🏷️ Basic Information

Make:

Jeep

Model:

Cherokee (XJ)

Year:

1991

Chassis Code:

XJ

Generation:

Second Generation (Facelifted)

👋 Introduction

Market Position:

The Jeep Cherokee (XJ) in 1991 was a highly popular compact SUV, known for its ruggedness, off-road capability, and versatility. It appealed to a broad market, from daily commuters to outdoor enthusiasts. This service manual caters to owners and mechanics who prioritize DIY maintenance and repairs for this enduring model.

Competitive Analysis:

In 1991, the XJ Cherokee competed with vehicles like the Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, and Toyota 4Runner. The Cherokee's unibody construction and coil-sprung solid front axle (on most 4x4 models) provided a distinct advantage in ride comfort and off-road articulation compared to some body-on-frame competitors.

Key Features:

Durable unibody construction, capable 4.0L inline-six engine, robust Selec-Trac or Command-Trac 4WD systems, comfortable ride for its class, excellent off-road potential, practical interior space, and a strong aftermarket support community.

📋 Manual Details

Coverage Areas:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Interior, Emissions Control, Diagnostics

Page Count:

Estimated 1000+ pages (typical for a comprehensive factory service manual)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable (likely PDF)

📖 Manual Coverage

Systems Covered:

Engine mechanical and electrical, fuel and emissions, cooling, lubrication, ignition, starting and charging, manual transmission, automatic transmission, transfer case, front and rear axles, suspension (front and rear), steering, brake system (hydraulic, ABS if applicable), climate control (HVAC), body electrical, interior systems, body panels and structure, glass, bumpers, lighting, safety restraints.

Procedures Included:

Routine maintenance, scheduled servicing, troubleshooting diagnostic procedures, component testing, repair and replacement of all major systems, engine overhaul, transmission overhaul, drivetrain component repair, suspension and steering alignment and repair, brake system servicing, electrical diagnostics and repair, HVAC system repair, bodywork and collision repair guidance, emissions system diagnosis and repair, torque specifications, wiring diagrams, vacuum diagrams, exploded views.

Technical Depth:

Comprehensive, ranging from basic fluid changes and inspections to complete engine and transmission rebuilds. Includes detailed diagnostic flowcharts, component specifications, and step-by-step repair instructions suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, clear diagrams and text suitable for printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine:

4.0L (242 ci) OHV Inline-6

Horsepower:

Approx. 190 hp @ 4700 RPM

Torque:

Approx. 235 lb-ft @ 3200 RPM

Fuel System:

Multi-Point Fuel Injection (MPI)

Engine Code:

AMC 242

Bore Stroke:

3.875 in x 3.563 in

Compression Ratio:

8.8:1

Firing Order:

1-5-3-6-2-4

Ignition System:

Distributorless Ignition System (DIS) or Distributor-based system depending on production date and specific market

Oil Capacity:

5 Quarts (4.7 Liters) with filter change

Oil Specification:

API SG or SH, SAE 10W-30 (check owner's manual for seasonal variations)

Alternator Output:

Typically 90-100 Amps

🔧 Transmission

Standard Transmission:

AX-5 5-Speed Manual (Rare for 4.0L, more common with 2.5L)

Optional Transmission:

AW4 4-Speed Automatic

Features:

AW4 is a robust electronically controlled automatic transmission (Aisin-Warner) known for its durability and smooth shifting. The AX-5 manual is a lighter-duty transmission.

Automatic Fluid Type:

ATF+3 or Mopar Dexron II/III (confirm with manual for exact specification)

Manual Fluid Type:

GL-3 or GL-4 SAE 75W-90 Gear Oil (for AX-5)

Transfer Case Options:

Selec-Trac (Part-Time with full-time 4WD option) or Command-Trac (Part-Time only)

📐 Dimensions

Wheelbase:

101.4 inches (2576 mm)

Length:

175.7 inches (4463 mm)

Width:

69.2 inches (1758 mm)

Height:

63.6 inches (1615 mm)

Ground Clearance:

Approx. 8.7 inches (221 mm) stock

Curb Weight:

Approx. 3300-3600 lbs (1497-1633 kg) depending on configuration

Towing Capacity:

Up to 5000 lbs (2268 kg) with proper equipment

Payload Capacity:

Approx. 1100 lbs (499 kg)

Cargo Volume:

Approx. 75 cubic feet (2124 liters) with rear seats folded

🛡️ Safety Features

NHTSA Front Impact Rating:

N/A (No rating for this model year by modern standards)

Active Features:

Four-wheel disc brakes (optional, standard on some trims), power-assisted steering.

Passive Features:

Three-point seat belts (front), two-point seat belts (rear), high-strength steel body structure.

Braking System:

Front: Ventilated discs, Rear: Drums standard; Optional Front: Disc, Rear: Disc with ABS.

Tire Size:

Common sizes include 225/75R15, 235/75R15 (check specific trim)

Wheel Bolt Pattern:

5x4.5 inches (5x114.3 mm)

💡 Technology Features

Infotainment System:

Basic AM/FM stereo radio with cassette player. Optional premium sound systems available. Digital clock.

Driver Assistance Features:

None typically associated with modern driver assistance systems (e.g., ABS was optional and basic).

Connectivity Options:

No integrated smartphone connectivity or Bluetooth.

Climate Control Type:

Manual HVAC system with fan speed and temperature controls. Optional A/C.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 6 months (traditional recommendation, depending on driving conditions)

Transmission Fluid Change Interval:

Every 30,000-50,000 miles for automatic, consult manual for manual transmission

Coolant Change Interval:

Every 30,000 miles or 2 years

Spark Plug Replacement:

Approx. 60,000-100,000 miles (depending on plug type, typically platinum)

Coolant Type:

Mopar Antifreeze/Coolant (Ethylene Glycol based, typically green)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+3 or Mopar Power Steering Fluid

Known Issues:

Headliner sagging, CPS (Crankshaft Position Sensor) failure on 4.0L, leaky valve cover gaskets, rear main seal leaks, rust (especially on rockers, floor pans, and rear quarter panels), automatic transmission overdrive issues (AW4), interior trim creaks, aging rubber bushings, minor electrical gremlins due to age.

Oil Filter Part Number:

Fram PH8A, Wix 51515, Purolator L30001 (example, verify for specific engine)

Air Filter Part Number:

Fram CA3550, Wix 42611 (example, verify for specific engine)

Serpentine Belt Part Number:

Gates K060940, Goodyear 6PK2385 (example, verify for specific engine and accessories)

📚 Vehicle History

Brand Heritage:

Jeep has a rich history dating back to World War II, synonymous with ruggedness and off-road prowess. The Cherokee line, introduced in 1974, was a groundbreaking vehicle, often credited with pioneering the compact SUV segment.

Model Evolution:

The XJ generation, introduced in 1984, was a revolutionary redesign for the Cherokee. It was the first American vehicle to feature a unibody chassis, offering a lighter, more rigid, and car-like ride compared to traditional body-on-frame SUVs. The 1991 model year marked a significant facelift with updated interior and exterior styling, including improved aerodynamics and a more modern dashboard.

Production Years:

1984-2001

Manufacturing Location:

Toledo, Ohio, USA

Ownership Changes:

During the XJ's production, Jeep transitioned from American Motors Corporation (AMC) to Chrysler Corporation in 1987.

🏆 Awards & Recognition

Recognitions:

The Jeep Cherokee XJ has consistently been recognized by automotive publications and enthusiasts as one of the best 4x4 vehicles of its era, lauded for its durability, off-road capability, and overall design. Often cited in 'greatest SUVs of all time' lists.

Ratings:

Consistently high owner satisfaction ratings for its reliability and capability, particularly the 4.0L engine.