🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ

Years Covered:

1991, 1992, 1993, 1994, 1995, 1996

Chassis Code:

XJ

Powertrain Codes:

2.5L I-4 (AMC 150), 4.0L I-6 (AMC 242)

👋 Introduction

Segment:

Compact SUV / Sport Utility Vehicle

Target Audience:

Off-road enthusiasts, general consumers seeking a durable and capable SUV, DIY mechanics

Competitors:

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

Design Philosophy:

Body-on-frame construction, solid rear axle, robust unibody design (for its era), proven drivetrain options

Platform:

AMC/Jeep XJ platform (unibody construction, revolutionary for its time)

📋 Manual Details

Systems Covered:

Engine Mechanical, Fuel System, Cooling System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Transfer Case, Driveshafts, Front Axle, Rear Axle, Suspension (Front & Rear), Steering, Brakes, Wheels & Tires, Body & Frame, HVAC System, Electrical System (Lighting, Ignition, Charging, Starting, Power Accessories), Diagnostic Procedures, Maintenance Schedules

Procedures Included:

Routine Maintenance, Inspection, Diagnosis, Troubleshooting, Repair, Overhaul, Replacement, Adjustment, Special Tool Usage

Estimated Pages:

1500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Cylinder Head, Block, Pistons, Rings, Crankshaft, Camshaft, Valves, Timing System

Fuel System:

Fuel Pump, Injectors, Fuel Lines, Fuel Tank, Pressure Regulator

Cooling System:

Radiator, Water Pump, Thermostat, Hoses, Fan, Coolant Specifications

Transmission Manual:

Clutch, Flywheel, Gearbox Overhaul, Shift Linkage, Fluid Specifications

Transmission Automatic:

Torque Converter, Valve Body, Gearsets, Seals, Fluid Specifications, Diagnostic Trouble Codes (DTCs)

Drivetrain:

Transfer Case Operation & Repair, Driveshaft U-Joints, Axle Bearings, Differential Rebuild

Suspension:

Front Leaf Spring/Coil Spring Suspension, Rear Leaf Spring Suspension, Shock Absorbers, Bushings, Ball Joints, Tie Rods

Brakes:

Front Disc Brakes, Rear Drum Brakes (or optional rear discs), Master Cylinder, Brake Lines, ABS System (if equipped), Bleeding Procedures

Steering:

Power Steering Pump, Steering Gearbox, Tie Rods, Steering Column

Electrical System:

Wiring Diagrams, Fuses, Relays, Lighting, Ignition System, Charging System, Starting System, Horn, Wiper/Washer System, Power Windows/Locks

HVAC:

A/C Compressor, Evaporator, Condenser, Heater Core, Blower Motor, Controls

Body And Frame:

Frame Inspection and Repair, Body Panel Replacement, Doors, Hood, Tailgate, Bumpers, Interior Trim

Diagnosis Troubleshooting:

Step-by-step diagnostic flowcharts for common and intermittent issues, symptom-based troubleshooting

Repair Overhaul:

Detailed instructions for engine, transmission, suspension, brake, and axle component repair and rebuilds

Maintenance:

Oil Change Intervals, Fluid Level Checks, Filter Replacements, Spark Plug Service, Belt Replacement

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures and electrical schematics.

📊 Manual Specifications

Format:

Searchable PDF

Quality:

High-resolution scans with clear text and diagrams

Printable:

Yes, all pages are printable

Binding:

Not Applicable (Digital)

Paper:

Not Applicable (Digital)

⚙️ Engine Specifications

Engine 1 Displacement:

2.5 Liters

Engine 1 Configuration:

Inline-4 Cylinder (I-4)

Engine 1 Code:

AMC 150

Engine 1 Horsepower:

~125 hp @ 4600 rpm (varies slightly by year)

Engine 1 Torque:

~170 lb-ft @ 2800 rpm (varies slightly by year)

Engine 2 Displacement:

4.0 Liters

Engine 2 Configuration:

Inline-6 Cylinder (I-6)

Engine 2 Code:

AMC 242 (High Output 'HO' version)

Engine 2 Horsepower:

~190 hp @ 4750 rpm (varies slightly by year)

Engine 2 Torque:

~220 lb-ft @ 3250 rpm (varies slightly by year)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

ECU:

Chrysler/Jeep proprietary engine control unit (ECU)

🔧 Transmission

Transmission Type Std:

5-Speed Manual (AX-5 for 2.5L, NV3550 later)

Transmission Type Opt:

3-Speed Automatic (A904/TF-904 for 2.5L), 4-Speed Automatic (Aisin AW-4/BA-10 for 4.0L)

Transfer Case:

Command-Trac (part-time 4WD) or Select-Trac (full-time/part-time 4WD options available)

📐 Dimensions

Length:

~167-170 inches

Width:

~69.9 inches

Height:

~63.7 inches

Wheelbase:

101.4 inches

Curb Weight Approx:

3,200 - 3,600 lbs

Gross Vehicle Weight Rating Gvwr Approx:

4,800 - 5,300 lbs

Cargo Volume Behind Rear Seat:

~32.5 cu ft

Cargo Volume With Rear Seat Folded:

~69.0 cu ft

🛡️ Safety Features

NHTSA Rollover Resistance:

4/5 stars (Varies by configuration)

ABS:

Optional, available on some models/trims

Traction Control:

Rarely equipped in this generation

Airbags:

Driver-side airbag standard from 1994 onwards; passenger airbag optional or not available prior.

Seatbelts:

Front 3-point, rear 3-point (later models)

💡 Technology Features

Audio System:

AM/FM stereo radio, cassette player, optional CD player. Speaker configurations varied by trim level.

Climate Control:

Manual HVAC controls, optional A/C. Later models saw minor dashboard revisions.

Cruise Control:

Optional on most trims

OBD Ii:

Pre-dates the mandatory OBD-II standard (1996). Uses older diagnostic connectors and proprietary codes.

🔧 Maintenance

Oil Change Frequency:

Every 3,000-5,000 miles or 6 months (depending on oil type and driving conditions)

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles; Manual: Check periodically, replace as needed or at higher mileage intervals.

Coolant Flush:

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

Engine Oil Type:

API SF/SG or higher. Viscosity: 10W-30 or 10W-40 (check owner's manual for exact temperature ranges).

Engine Oil Capacity:

2.5L I-4: 4.5 quarts (with filter); 4.0L I-6: 6.0 quarts (with filter)

Transmission Fluid Type Auto:

ATF+3 or equivalent (e.g., Mopar ATF+3, Dexron III compatible where specified)

Transmission Fluid Type Manual:

GL-3 or GL-4 Gear Oil (specific weight depends on transmission model, e.g., 75W-90 or 80W-90)

Coolant Type:

Ethylene Glycol based Antifreeze (e.g., Mopar Antifreeze/Coolant, green type)

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or Dexron II/III compatible

Common Problems:

Head gasket leaks (especially 4.0L I-6), Cooling system leaks (radiator, hoses), Differential pinion seal leaks, Transfer case chain stretch, Rust (especially rocker panels and rear quarter panels), Window regulators, CPS (Crankshaft Position Sensor) failure on later models, Steering gearbox wear.

📚 Vehicle History

Jeep Legacy:

Jeep's long history of producing rugged, off-road capable vehicles dating back to WWII.

Introduction Year:

1984 (XJ generation)

Updates 1991-1996:

Facelift in 1991 introduced new interior and exterior styling, including revised dashboard, improved ergonomics, and updated front fascia. Introduction of driver-side airbag around 1994. Minor powertrain updates and emissions controls.

Production Location:

Toledo, Ohio, USA

Production Period:

1984-2001 (North America)

🏆 Awards & Recognition

Off Road Prowess:

Consistently praised for its off-road capability and durability, often considered a benchmark in its class.

Long Term Reliability:

Mixed reviews, with the 4.0L engine generally lauded for longevity, but known issues require diligent maintenance. Often considered reliable due to simplicity and availability of parts.

Emission Standards:

Compliant with US Federal Emission Standards for the respective model years. Specifics vary by state and year.