🏷️ Basic Information

Make:

Jeep

Model:

Cherokee (XJ)

Year:

1991

Chassis Code:

XJ

👋 Introduction

Market Position:

The 1991 Jeep Cherokee XJ represents a pivotal year in the evolution of the compact SUV segment. Known for its ruggedness, off-road capability, and unibody construction, the XJ was a dominant force, appealing to both off-road enthusiasts and everyday drivers seeking utility and durability.

Competitive Analysis:

Competitors in 1991 included vehicles like the Ford Explorer, Chevrolet S-10 Blazer, Nissan Pathfinder, and Toyota 4Runner. The XJ's distinct advantage lay in its smaller footprint, legendary Selec-Trac and Command-Trac 4x4 systems, and its Jeep heritage.

Key Features:

Durable unibody construction, robust 4x4 systems, comfortable yet capable ride, iconic Jeep styling, and a strong aftermarket support ecosystem.

📋 Manual Details

Coverage Areas:

Comprehensive repair and service for 1991 Jeep Cherokee (XJ).

Page Count:

Estimated 1500-2000 pages (typical for a full factory service manual).

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine mechanical, fuel system, cooling system, ignition system, exhaust system, manual transmission, automatic transmission, transfer case, drivetrain, suspension (front and rear), steering, brakes, electrical system (including wiring diagrams), HVAC system, body and chassis, interior trim, emissions control systems.

Procedures Included:

Routine maintenance, diagnostics, troubleshooting, component removal and installation, adjustments, rebuild procedures, torque specifications, electrical system schematics, diagnostic trouble codes (DTCs), lubrication, fluid capacities and types.

Technical Depth:

Professional level diagnostics, repair, and overhaul. Suitable for experienced technicians and advanced DIY enthusiasts.

Wiring Diagrams:

Detailed electrical schematics for all major vehicle systems, including engine control, lighting, accessories, and power distribution.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon problems, including symptom-based troubleshooting.

Torque Specifications:

Comprehensive list of all critical torque specifications for engine, transmission, suspension, brakes, and chassis components.

Diagnostic Trouble Codes:

Listing of OBD-I diagnostic codes (where applicable) and their meanings for engine and system diagnostics.

Body And Chassis Repair:

Procedures for body panel alignment, door and window repair, interior trim removal and installation, and chassis component maintenance.

Suspension And Steering Repair:

Detailed instructions for servicing and replacing components such as ball joints, tie rod ends, control arm bushings, leaf springs, shock absorbers, and steering gearbox.

HVAC System Service:

Information on air conditioning system operation, refrigerant handling, heater core replacement, blower motor service, and diagnostic procedures for climate control issues.

Wheel And Tire Specifications:

Recommended tire sizes (e.g., P215/75R15, P225/75R15), wheel bolt pattern (5x4.5 inches / 5x114.3mm), and recommended tire pressures.

Engine Rebuild Procedures:

Comprehensive guides for engine disassembly, inspection, cleaning, and reassembly, including piston ring gap, bearing clearance, and valve seating specifications.

Transmission Rebuild Procedures:

Detailed steps for overhauling the AX-5 manual and AW4 automatic transmissions, including torque converter testing and clutch pack replacement.

📊 Manual Specifications

File Format:

Searchable PDF, optimized for digital viewing and printing.

Print Quality:

High-resolution scanned pages, clear diagrams and illustrations.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine:

4.0L (242 CID) Inline 6-Cylinder (OHV)

Secondary Engine:

2.5L (150 CID) Inline 4-Cylinder (OHV)

Horsepower 4.0L:

190 hp @ 4750 RPM

Torque 4.0L:

220 lb-ft @ 3000 RPM

Horsepower 2.5L:

130 hp @ 4750 RPM

Torque 2.5L:

175 lb-ft @ 3000 RPM

Fuel System:

Multi-Point Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) or distributor with coil-on-plug (depending on specific build date/variant within 1991).

Cooling System:

Pressurized, liquid-cooled with radiator, fan, and thermostat.

Engine Management:

Chrysler's engine control unit (ECU) for fuel delivery, ignition timing, and emissions control.

🔧 Transmission

Standard Transmission:

AX-5 5-speed manual transmission

Optional Transmission:

AW4 4-speed automatic transmission

Transmission Fluid 4.0L Auto:

ATF+4 (or equivalent Dexron III/Mercon prior to ATF+4 adoption)

Transmission Fluid 2.5L Manual:

API GL-4 gear oil, 75W-90

Transfer Case Options:

2WD (Command-Trac NV131), 4WD part-time (Selec-Trac NP231), 4WD full-time (Selec-Trac NP242).

Transfer Case Fluid:

ATF+4 (for NP231/NP242) or equivalent.

📐 Dimensions

Exterior Length:

Approximately 165.4 inches (4201 mm)

Exterior Width:

Approximately 69.3 inches (1760 mm)

Exterior Height:

Approximately 63.7 inches (1618 mm)

Wheelbase:

101.4 inches (2576 mm)

Ground Clearance:

Varies by trim and suspension, typically around 8 inches (203 mm) or more.

Curb Weight:

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

Cargo Volume:

Approximately 69.0 cubic feet (1.95 cubic meters) with rear seats folded.

🛡️ Safety Features

Ratings:

NHTSA ratings for this era are generally considered dated; specific crash test data for 1991 may be limited compared to modern standards.

Active Features:

Four-wheel drive systems (optional/standard), power-assisted brakes (front disc/rear drum).

Passive Features:

Seat belts, reinforced unibody structure.

Braking System:

Front: Ventilated Disc; Rear: Drum (optional rear disc on some higher trims/export models).

ABS:

Anti-lock Braking System (ABS) was optional on some models for 1991.

💡 Technology Features

Infotainment:

Basic AM/FM radio with cassette player, optional CD player. Manual climate controls.

Driver Assistance:

Limited to ABS on some models. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane-keeping assist.

Connectivity:

No integrated Bluetooth or USB connectivity. Aftermarket solutions are common for modernizing.

Gauges And Instruments:

Analog gauges for speedometer, tachometer (on some trims), fuel level, coolant temperature, oil pressure, and voltmeter. Warning lights for system faults.

🔧 Maintenance

Service Intervals Oil:

3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type used.

Service Intervals Transmission Fluid:

24,000-30,000 miles (38,000-48,000 km) or 24-36 months for automatic transmissions; clutch fluid check per manual.

Service Intervals Coolant:

30,000 miles (48,000 km) or 24 months, or every 2 years/50,000 miles with HOAT coolant.

Fluid Specifications Engine Oil:

SAE 10W-30 (check owner's manual for specific temperature ranges).

Fluid Specifications Coolant:

Mopar Antifreeze/Coolant (or equivalent HOAT, typically 50/50 mix with distilled water).

Fluid Specifications Brake Fluid:

DOT 3 brake fluid.

Known Issues:

Head gasket leaks (especially on early 4.0L), rear main seal leaks, radiator failure, transfer case drop (for driveline vibration), exhaust manifold cracks (4.0L), starter issues, rust (frame and body).

Tune Up Components:

Spark plugs (e.g., Champion Copper Plus), spark plug wires, distributor cap and rotor (if applicable), air filter, fuel filter.

Common Upkeep:

Regularly inspect and service the cooling system, drivetrain components (U-joints), suspension bushings, and check for exhaust leaks.

📚 Vehicle History

Brand Heritage:

Jeep, a brand with deep military roots and a reputation for off-road prowess, has been synonymous with adventure and capability for decades.

Model Evolution:

The XJ Cherokee, introduced in 1984, was revolutionary for its unibody construction, setting it apart from traditional body-on-frame SUVs. It was praised for its lighter weight, improved on-road manners, and retained off-road capability. The 1991 model year saw updates including revised interior and exterior styling, and the introduction of the more powerful 4.0L HO engine as standard on many models.

Production:

The Jeep Cherokee (XJ) was produced from 1984 to 2001 in North America, with the 1991 model being part of the second generation facelift.

🏆 Awards & Recognition

Recognitions:

The Jeep Cherokee XJ, throughout its production run, was consistently praised by automotive journalists and enthusiasts for its engineering, off-road capability, and value. While specific 'awards' for the 1991 model may not be as widely documented as modern vehicles, its enduring popularity and cult status are testaments to its design.

Ratings:

Frequently cited in 'best SUV' or 'best off-road vehicle' lists for its era.