Segment:
Compact SUV, known for its off-road capability and rugged design
Target Audience:
Owners, DIY mechanics, professional technicians seeking comprehensive repair information
Competitors Era:
Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, Toyota 4Runner
Design Philosophy:
Unibody construction (unique for its time in this segment) for improved ride comfort and reduced weight, solid rear axle for durability
Off Road Capability:
Command-Trac (231) and Selec-Trac (242) 4WD systems, good approach/departure angles, ground clearance
Primary Coverage:
Full factory service, repair, and workshop procedures
Secondary Coverage:
Diagnostics, troubleshooting, wiring diagrams, specifications
Estimated Page Count:
Likely exceeds 1500 pages (typical for a comprehensive factory manual of this era)
Type:
Factory Service Manual / Workshop Manual
Format:
PDF (Downloadable)
Powertrain:
Engine mechanical (4.0L I6, 2.5L I4), fuel system, ignition system, exhaust system, cooling system, lubrication system
Transmission:
Manual (AX-5, AX-15) and Automatic (AW4, 30RH) transmission repair, overhaul, and diagnostics
Drivetrain:
Transfer case (NP231, NP242), front and rear axle assembly (Dana 30, Dana 35), drive shafts, CV joints
Suspension:
Front and rear suspension components, steering system, power steering, alignment specifications
Brakes:
Front and rear brake systems (disc/drum configurations), ABS diagnostics and repair (if equipped)
Electrical:
Complete wiring diagrams, lighting, starter, alternator, battery, fuse box, relays, instrument cluster, body control modules
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Body:
Body panels, doors, windows, interior trim, seats, bumpers, underbody coatings
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication points
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides for all major systems
Repair:
Component removal and installation, disassembly and reassembly, specialized repair techniques
Diagnostics:
OBD-I diagnostics (for early models) and OBD-II diagnostics (for later models), sensor testing, actuator testing
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission overhauls
Specificity:
Detailed torque specifications, clearances, timing settings, and assembly sequences
Quality:
High-resolution PDF, allowing for clear viewing and printing of diagrams and text
Searchability:
Likely text-searchable PDF, enabling quick access to specific information
Print Recommendation:
Printable pages for on-the-go reference in a workshop environment
Binding For Digital:
Not applicable (Digital Download)
Paper For Printed:
Not applicable (Digital Download)
Engine 1:
4.0L (242 cubic inch) inline 6-cylinder OHV 'Power-Tech' I6
Engine 2:
2.5L (150 cubic inch) inline 4-cylinder OHV 'Tech' I4
4.0L Horsepower:
Approximately 180-190 hp (varies slightly by year and tune)
4.0L Torque:
Approximately 220-230 lb-ft (varies slightly by year and tune)
2.5L Horsepower:
Approximately 125-130 hp
2.5L Torque:
Approximately 150-155 lb-ft
Fuel Delivery:
Electronic Fuel Injection (EFI) - Multi-port for 4.0L, Throttle Body Injection (TBI) for 2.5L (early in the range), transitioning to MPI for 2.5L
Recommended Fuel:
Unleaded gasoline, 87 octane minimum
System Type:
Distributorless Ignition System (DIS) or Distributor with Ignition Coil
Transmission 1:
5-speed manual transmission (AX-5 for 2.5L, AX-15 for 4.0L)
Transmission 2:
3-speed automatic transmission (30RH)
Transmission 3:
4-speed automatic transmission (AW4)
Aw4 Features:
Electronically controlled, known for durability and smooth shifting
Atf Type:
ATF+4 (or equivalent DEXRON III for earlier models) for automatic transmissions
Manual Fluid Type:
API GL-3 or GL-4 gear oil (e.g., 75W-90) for manual transmissions
Wheelbase:
101.4 inches (2576 mm)
Length:
167.2 inches (4247 mm) for 2-door, 172.5 inches (4382 mm) for 4-door
Width:
69.9 inches (1775 mm)
Height:
63.4 inches (1610 mm)
Curb Weight:
Approximately 3,200 - 3,600 lbs (1450 - 1630 kg) depending on configuration
Gross Vehicle Weight Rating Gvw:
Typically around 4,600 - 5,000 lbs (2087 - 2268 kg)
NHTSA Rollover Resistance:
Three-star rating (for 4-door models, typical for SUVs of this era)
ABS:
Optional Anti-lock Braking System (ABS) on rear wheels, later models may have 4-wheel ABS
Airbags:
Driver's side airbag standard from 1994 onwards
Seatbelts:
3-point front seat belts, 2-point rear lap belts (later models may have 3-point rear belts)
Oil Change:
Every 3,000-5,000 miles or 6 months (depending on oil type and driving conditions)
Engine Air Filter:
Every 15,000-30,000 miles
Spark Plugs:
Every 30,000-60,000 miles (depending on plug type)
Engine Oil Type:
SAE 10W-30 or 10W-40 (check owner's manual for specific viscosity based on temperature)
Engine Oil Capacity:
5 quarts (4.7 liters) for 4.0L I6, 5 quarts (4.7 liters) for 2.5L I4
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water (Mopar or equivalent)
Engine 4.0L:
Cracked cylinder heads (early revisions), intake manifold gasket leaks, head gasket leaks, tappet noise (lifter tick)
Transmission Aw4:
Solenoid failures, torque converter issues, leaking seals
Electrical:
Cracked dashboard housings, intermittent gauge failures, power window regulator issues, CPS (Crankshaft Position Sensor) failure on 4.0L
Suspension Steering:
Worn ball joints, tie rod ends, control arm bushings, steering box wear
Body:
Rust in rocker panels, rear quarter panels, and floor pans
Jeep Legacy:
Founded on robust military vehicles, Jeep has a long-standing reputation for off-road prowess and durability.
Xj Generation:
The XJ Cherokee (introduced in 1984) was revolutionary as the first compact SUV with unibody construction. This generation (1991-1996) received significant updates.
1991 Updates:
Introduction of the 4.0L HO (High Output) engine, improved interior styling, new dashboard, driver's side airbag introduced in later years.
1994 Facelift:
Major exterior refresh including new front and rear fascias, revised grille, new hood, and updated interior with dual airbags as standard.
Production Location:
Toledo, Ohio, USA
Motor Trend SUV Of The Year:
Cherokee XJ named Motor Trend's Truck of the Year in 1988 (though this manual covers later years, it highlights the model's success)
Off Road Magazine Acclaim:
Consistently praised by off-road publications for its capability and aftermarket support.
