Jeep CHEROKEE XJ 1992-1996 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Model Range: Cherokee Model Code: XJ Model Generation: Second Generation (XJ) Market Segment: Compact SUV Codes Chassis Code: XJ 👋 Introduction Market Position Segment Leadership: Pioneering compact SUV with significant off-road capability and durability Competitive Analysis Key Competitors: Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Mitsubishi Montero Key Features Unibody Construction: Lightweight and strong unibody construction, a significant departure for SUVs at the time Off Road Prowess: Renowned for its off-road capability, especially with the Command-Trac (NV231) and Selec-Trac (NV242) transfer cases Powertrain Durability: Praised for the robust and reliable 4.0L 'High Output' inline-six engine 📋 Manual Details Coverage Areas Regions Covered: North America (US/Canada Models) Page Count Estimated Page Count: 1500-2000+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnostics, repair of 4.0L I6 and 2.5L I4 engines Engine Performance: Fuel injection, ignition system, emission controls, cooling system Transmission Automatic: 30RH, 32RH (TF-999/TF-30) overhaul, diagnostics, repair Transmission Manual: AX-5, AX-15 overhaul, diagnostics, repair Drivetrain: Front and rear axles (Dana 30, Dana 35c), transfer cases (NP231, NP242), driveshafts, U-joints Suspension Steering: Front and rear suspension, steering system, power steering, linkage, alignment specifications Brakes: Front and rear disc/drum brake systems, ABS (if equipped), hydraulic system, parking brake Electrical System: Battery, charging system, starting system, lighting, instrumentation, power accessories, wiring diagrams Body Exterior: Body panels, doors, hood, tailgate, glass, bumpers, trim Body Interior: Seats, dashboard, interior trim, HVAC system, audio system Heating Ventilation Air Conditioning: HVAC system diagnosis and repair, A/C refrigerant, blower motor Safety Restraint Systems: Seat belts, airbags (if equipped), general safety information Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides Major Repairs: Engine rebuilds, transmission overhauls, driveline component replacement Component Replacement: Alternator, starter, water pump, fuel pump, brake calipers, radiators Electrical Diagnostics: Circuit testing, component testing, wiring harness repair Suspension Alignment: Wheel alignment procedures and specifications Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine/transmission rebuilds) 📊 Manual Specifications File Format Compatibility: Win95/98/ME/XP/vista/7/8/8.1/10/Linux/MAC/IOS/Android Print Quality Scan Quality: High-resolution, clear text and diagrams Binding Type Binding: Digital (PDF) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 4.0 L (242 cu in) Engine 1 Configuration: Inline 6-cylinder (I6) Engine 1 Valvetrain: Overhead Valve (OHV), 12 valves Engine 1 Bore X Stroke: 3.875 x 3.56 in (98.4 x 90.5 mm) Engine 1 Compression Ratio: 8.8:1 Engine 1 Horsepower Est: 190 hp @ 4750 rpm (1991-1996) Engine 1 Torque Est: 220 lb-ft @ 3250 rpm (1991-1996) Secondary Engine Engine 2 Displacement: 2.5 L (150 cu in) Engine 2 Configuration: Inline 4-cylinder (I4) Engine 2 Valvetrain: Overhead Valve (OHV), 8 valves Engine 2 Bore X Stroke: 3.875 x 3.375 in (98.4 x 85.7 mm) Engine 2 Compression Ratio: 8.8:1 Engine 2 Horsepower Est: 125 hp @ 4600 rpm (1992-1996) Engine 2 Torque Est: 150 lb-ft @ 3400 rpm (1992-1996) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Recommended Octane: 87 AKI (Regular) 🔧 Transmission Standard Transmission Manual Transmission Standard: AX-15 5-speed manual (late 1993-1996 models with 4.0L, some earlier) Optional Transmission Automatic Transmission Optional: 30RH (TF-999) 3-speed automatic (2.5L and early 4.0L models) Optional Transmission 2 Automatic Transmission Optional 2: 32RH (TF-30) 3-speed automatic (late 1993-1996 models with 4.0L) Features Transfer Case Options: Command-Trac (NV231) part-time 2-speed, Selec-Trac (NV242) full-time 2-speed Fluid Specifications Automatic Transmission Fluid: ATF+3 (Chrysler Mopar) Manual Transmission Fluid: Mopar Manual Transmission Lubricant or equivalent (e.g., Synchromesh) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 167.5 inches (4255 mm) Width: 70.5 inches (1791 mm) Height: 64.4 inches (1636 mm) Ground Clearance Est: 8.7 inches (221 mm) Weights Curb Weight Est: 3300-3700 lbs (1497-1678 kg) Gross Vehicle Weight Rating Gvw: Approx. 4700-5000 lbs (2132-2268 kg) 🛡️ Safety Features Ratings NHTSA Rollover Resistance Rating: 3 stars (estimated) Active Features ABS: Available (Rear-wheel anti-lock brakes typically) Passive Features Airbags: Driver-side airbag standard from 1994 onwards Seat Belts: Three-point seat belts in front, two-point lap belts in rear (upgradeable to three-point) 💡 Technology Features Infotainment Audio System: Factory AM/FM/Cassette or AM/FM/CD player (optional) Speakers: Typically 4-6 speakers Driver Assistance Cruise Control: Available Connectivity Power Windows Locks: Available on higher trim levels 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions (consult manual for specifics) Engine Air Filter: Inspect every 15,000 miles (24,000 km), replace as needed Spark Plugs: Replace every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., platinum plugs can extend intervals) Coolant Flush: Every 30,000 miles (48,000 km) or 2 years Transmission Fluid Change: Every 30,000-60,000 miles (48,000-96,000 km) for automatic; inspect manual transmission fluid annually Fluid Specifications Engine Oil...
Rust in floor pans, rocker panels, tailgate, and unibody frame rails
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Built upon Jeep's long history of rugged, go-anywhere vehicles originating from WWII.
Model Evolution
Xj Introduction:
Introduced in 1984 as a revolutionary compact SUV with unibody construction. The 1992-1996 period represents a significant refresh and refinement of the XJ.
Facelift 1992:
Key updates for 1992 included a revised interior, improved aerodynamics with smoother body lines, updated dashboard, and the introduction of the more powerful 4.0L I6 engine with increased horsepower.
Engine Upgrade 1991:
The 4.0L 'High Output' engine, introduced in late 1990 for the 1991 model year, became the dominant engine option, known for its torque and reliability.
Production
Production Start Year:
1984
Production End Year:
2001 (North America), 2016 (Egypt)
Production Period Covered
Manual Years:
1992, 1993, 1994, 1995, 1996
🏆 Awards & Recognition
Recognitions
Four Wheeler Magazine:
Often praised by off-road publications for its capability and durability.
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