🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ

Model Years Covered:

1991, 1992, 1993, 1994, 1995, 1996

Chassis Code:

XJ

Production Platform:

Unibody

👋 Introduction

Vehicle Segment:

Compact SUV / Off-road Vehicle

Target Audience:

Enthusiasts, DIY mechanics, fleet maintenance, off-roaders.

Key Competitors:

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

Chassis Design:

Revolutionary unibody construction for its time, offering a balance of on-road comfort and off-road capability.

Off Road Prowess:

Renowned for its off-road capability due to solid axles (front and rear), and available 4WD systems (Command-Trac, Selec-Trac).

Engine Options:

Robust and reliable inline-6 engine, a staple of Jeep's performance.

📋 Manual Details

Primary Coverage:

Workshop Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Repair Procedures

Estimated Pages:

Approximately 1500-2000+ (typical for comprehensive workshop manuals of this era)

Type:

Service and Repair Manual

Language:

English

Format:

Likely Digital (PDF), potentially Print Replica

📖 Manual Coverage

Engine Mechanical:

All aspects of 2.5L I-4 and 4.0L I-6 engines, including disassembly, assembly, inspection, and overhaul.

Engine Fuel System:

Fuel injection systems (MPI), fuel pump, fuel injectors, fuel pressure regulator, fuel lines, and diagnostic procedures.

Cooling System:

Radiator, water pump, thermostat, hoses, fan (mechanical and electric), coolant specifications, and troubleshooting.

Lubrication System:

Oil pump, oil filter, oil pan, oil passages, lubrication specifications, and oil change procedures.

Ignition System:

Spark plugs, ignition coils, distributor (early models), crankshaft position sensor, camshaft position sensor, and timing.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors, and related components.

Transmission Manual:

NV2500, NV3550 (later years) - clutch, gearbox, shift linkage, and maintenance.

Transmission Automatic:

Select-A-Ride, NP242, NP231 transfer cases - removal, installation, internal repair, fluid specifications.

Driveline:

Driveshafts, U-joints, CV joints, axle shafts, differentials, and propeller shafts.

Front Suspension:

Solid front axle (Dana 30), control arms, coil springs, shock absorbers, sway bar, ball joints, and steering linkage.

Rear Suspension:

Leaf spring solid axle, shock absorbers, sway bar, bushings, and trailing arms.

Steering:

Power steering system, steering column, steering gear, tie rods, and steering damper.

Brakes Front:

Disc brakes, calipers, rotors, brake pads, brake lines, and ABS (where applicable).

Brakes Rear:

Drum brakes or disc brakes (depending on trim/year), brake shoes, drums, brake lines, and parking brake system.

Electrical System Charging:

Alternator, voltage regulator, battery, and wiring.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch, and related circuits.

Electrical System Lighting:

Headlights, taillights, interior lighting, fog lights, and related switches/relays.

Electrical System Accessories:

Power windows, power door locks, mirrors, radio, HVAC controls, and related wiring harnesses.

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, trim, glass, and weatherstripping.

Body Interior:

Seats, dashboard, interior trim, carpeting, headliner, and seat belts.

HVAC:

Heating, ventilation, air conditioning system components, controls, refrigerant, and troubleshooting.

Scheduled Maintenance:

Detailed procedures for oil changes, filter replacements, fluid checks and changes, tune-ups, and inspections.

Diagnostic Troubleshooting:

Systematic diagnostic flowcharts and procedures for identifying and resolving common and uncommon faults.

Repair Overhaul:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Recalibration Adjustment:

Procedures for adjusting brakes, clutch, steering, and other critical components.

Electrical Troubleshooting:

Wiring diagrams, component testing, circuit tracing, and diagnosis of electrical issues.

Body Repair:

Procedures for dent repair, panel replacement, rust repair, and glass replacement.

Lubrication Points:

Specific lubrication points and recommended lubricants for various chassis components.

Depth Level:

Comprehensive: Covers from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.

Diagnostic Tools:

Mentions necessary special tools, torque wrenches, and diagnostic equipment.

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all major systems.

Torque Specifications:

Provides torque specifications for all critical fasteners.

Diagnostic Codes:

May include OBD-I (On-Board Diagnostics) codes and diagnostic procedures specific to the era.

📊 Manual Specifications

Digital Quality:

High-resolution scans, searchable text (if OCR'd), well-organized sections.

Print Replica Quality:

Clear, legible text and diagrams, comparable to original factory manuals.

Physical Manual Binding:

Stitched, perfect bound, or spiral bound for durability and lay-flat functionality (if printed).

Physical Manual Paper:

Durable paper stock, often with a matte finish to reduce glare.

⚙️ Engine Specifications

Engine 1 Displacement Type:

2.5L Inline-4 (AMC 150)

Engine 1 Horsepower:

Approx. 125 hp @ 4800 rpm (varies slightly by year)

Engine 1 Torque:

Approx. 145 lb-ft @ 3200 rpm (varies slightly by year)

Engine 2 Displacement Type:

4.0L Inline-6 (AMC 242)

Engine 2 Horsepower:

Approx. 180-190 hp @ 4750 rpm (varies slightly by year)

Engine 2 Torque:

Approx. 220-225 lb-ft @ 3200 rpm (varies slightly by year)

Induction System:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

20 US Gallons (standard)

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transmission (e.g., AX-5 for 2.5L, AX-15 for 4.0L)

Transmission Type Optional:

4-speed Automatic Transmission (e.g., AW4)

Transfer Case Options:

Command-Trac (2WD/4WD Part-Time) or Selec-Trac (2WD/4WD Full-Time/Part-Time) NP231 or NP242

Gear Ratios Manual:

Refer to manual for specific ratios of AX-5 and AX-15.

Gear Ratios Automatic:

Refer to manual for specific ratios of AW4.

Transmission Fluid Spec Auto:

ATF+3 (Chrysler's proprietary fluid, often equivalent to Dexron-III) - Refer to manual for exact specification.

Transmission Fluid Spec Manual:

GL-3 or GL-4 rated gear oil for manual transmissions - Refer to manual for exact specification and viscosity.

📐 Dimensions

Wheelbase:

101.4 inches (2576 mm)

Length:

164.4 - 173.0 inches (4176 - 4394 mm) (depending on bumper/spare tire carrier)

Width:

69.3 inches (1760 mm)

Height:

63.5 - 66.0 inches (1613 - 1676 mm) (depending on suspension/roof rack)

Curb Weight:

Approx. 3100 - 3600 lbs (1406 - 1633 kg) (depending on engine, drivetrain, and trim)

Gross Vehicle Weight Rating Gvw:

Refer to vehicle's specific VIN plate for accurate GVWR.

Towing Capacity:

Up to 5,000 lbs (2268 kg) with proper equipment and engine.

🛡️ Safety Features

NHTSA Rollover Resistance:

Refer to specific model year NHTSA data; likely a moderate risk factor common to SUVs of this era.

ABS:

Optional Anti-lock Braking System (ABS) on front wheels and rear wheels (standard on some later models).

Four Wheel Drive:

Available Command-Trac or Selec-Trac 4WD systems provide enhanced traction.

Airbags:

Driver-side airbag introduced around 1994; passenger airbag was not standard or widely available during this period.

Seatbelts:

Three-point front seat belts, two-point rear lap belts (later models may have three-point rear belts).

💡 Technology Features

Audio System:

Factory AM/FM radio, cassette player, optional CD player. Speaker configurations vary by trim. Aftermarket upgrades are common.

Cruise Control:

Available as an option on most trims.

Anti Lock Brakes:

Optional ABS system, primarily affecting front wheels and rear axle, with varying implementation across model years.

Diagnostic Interface:

OBD-I port (On-Board Diagnostics first generation); requires specific connectors and diagnostic tools for fault code retrieval.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (recommendation varies by oil type and driving conditions).

Air Filter Replacement:

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

Spark Plug Replacement:

Every 30,000-60,000 miles (depending on plug type: copper, platinum, or iridium).

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Engine Oil Spec:

10W-30 or 10W-40 for 4.0L I-6; 5W-30 or 10W-30 for 2.5L I-4 (refer to manual for exact API service classification).

Engine Oil Capacity:

4.0L I-6: 5 quarts (4.7 liters); 2.5L I-4: 5 quarts (4.7 liters) with filter change.

Coolant Type:

Ethylene Glycol based, typically green in color. Mopar Antifreeze/Coolant (OAT or HOAT) is recommended. Refer to manual for specific type.

Brake Fluid Spec:

DOT 3 or DOT 4; refer to manual for exact specification.

Common Problems Engine:

Head gasket leaks (especially 4.0L), oil filter adapter leaks, cracked exhaust manifolds (4.0L), CPS (Crankshaft Position Sensor) failures.

Common Problems Suspension Steering:

Worn ball joints, tie rod ends, and steering stabilizer; leaf spring sag in the rear.

Common Problems Electrical:

Corroded grounds, faulty ignition switch, power window regulator failures, interior wiring harness issues.

Common Problems Body:

Rust in rocker panels, floor pans, and rear quarter panels; tailgate rust; door handle failures.

📚 Vehicle History

Brand Origin:

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

Cherokee Xj Introduction:

The Cherokee XJ was introduced in 1984, revolutionizing the SUV market with its unibody construction.

Major Updates 1991-1996:

Significant updates included revised exterior styling (new grille, bumpers, lighting), improved interior ergonomics, increased engine power (especially the 4.0L), introduction of airbags (late models), and refinements to the powertrain and suspension.

Production Period:

1984-2001 (North America), 1984-2002 (International)

Manufacturing Locations:

Primarily Toledo, Ohio, USA.

🏆 Awards & Recognition

Off Road Magazine Rankings:

Consistently ranked as one of the best off-road vehicles by publications like Four Wheeler Magazine during its production run.

Automotive Journalism Acclaim:

Praised for its capability, durability, and innovative unibody design by various automotive critics.