1990 Jeep Cherokee XJ Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: XJ Year: 1990 👋 Introduction Market Position Vehicle Class: Compact SUV Target Audience Manual: Jeep owners, independent repair shops, automotive enthusiasts. Competitive Analysis Competitors Vehicle 1990: Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, Toyota 4Runner Key Features Vehicle Unibody Construction: Pioneering unibody construction for an SUV, offering lighter weight and improved ride compared to body-on-frame rivals. Off Road Capability: Renowned off-road prowess due to Command-Trac (2WD/4WD) or Selec-Trac (full-time 4WD) transfer cases and robust drivetrain options. Key Features Manual Completeness: Comprehensive, factory-level information essential for accurate diagnosis and repair. Value Proposition: Enables cost-effective maintenance and repairs, extending the lifespan and preserving the value of the vehicle. 📋 Manual Details Identification Manual Type: Factory Service Manual / Repair Manual Language: English Format: Digital (likely PDF, as implied by 'Repair Manual Software') 📖 Manual Coverage Systems Engine Mechanical: Comprehensive coverage including disassembly, inspection, assembly, and troubleshooting for all engine variants. Engine Electrical: Detailed diagrams and troubleshooting for ignition, fuel injection, starting, charging, and emissions control systems. Transmission Manual: Service and repair procedures for manual transmissions (e.g., AX-5, BA-10/5). Transmission Automatic: Service and repair procedures for automatic transmissions (e.g., AW-4). Drivetrain 4X4: Detailed information on transfer case (e.g., NP231), front and rear axle assemblies, and hub operation. Suspension: Front and rear suspension components, including leaf springs, shock absorbers, control arms, and steering linkage. Steering: Power steering system components, hydraulic pump, steering box/rack, and linkage. Brakes: Front disc brakes, rear drum brakes, parking brake system, hydraulic lines, master cylinder, and ABS (if equipped). Body And Frame: Body panel removal/installation, door mechanisms, glass, roof, and unibody structural components. Electrical System: Complete wiring diagrams, lighting, gauges, interior controls, horn, wipers, and HVAC electrical components. Heating Ventilation Air Conditioning: HVAC system components, refrigerant charging, blower motor, heater core, and A/C compressor. Procedures Routine Maintenance: Oil changes, fluid checks and replacements, filter replacements, spark plug service, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems, often with flowcharts. Component Replacement: Step-by-step instructions for replacing major and minor components across all vehicle systems. Diagnostics: Detailed diagnostic steps, including use of diagnostic tools and interpretation of sensor data (OBD-I for this era). Rebuilds: Comprehensive procedures for rebuilding engines, transmissions, transfer cases, and axles. Technical Depth Depth Level: In-depth, professional level suitable for dealership technicians and experienced DIY mechanics. 📊 Manual Specifications File Properties File Format: PDF (typically, for digital versions) Searchability: Likely fully text-searchable for quick access to specific topics. Printability: Printable pages, allowing for physical reference. Physical Properties Page Count Estimated: 1000-2000 pages (typical for a comprehensive factory service manual of this era). Print Quality: High-resolution scans/digital reproductions ensuring clarity of diagrams and text. Binding Type: N/A (for digital format) Paper Type: N/A (for digital format) ⚙️ Engine Specifications Primary Engine 1 Engine Code: 4.0L I-6 (High Output) Engine Displacement: 3957 cc (242 ci) Engine Configuration: Inline 6-cylinder, Overhead Valve (OHV) Bore X Stroke: 3.875 in x 3.563 in (98.4 mm x 90.5 mm) Compression Ratio: 8.8:1 Horsepower Net: 177 hp @ 4750 rpm (approx.) Torque Net: 220 lb-ft @ 3250 rpm (approx.) Fuel System: Multi-point Fuel Injection (MPI) Ignition System: Distributorless Ignition System (DIS) with coil packs (later models) or Distributor with Ignition Coil. Cooling System Capacity: 10.5 US quarts (9.9 L) Oil Capacity W Filter: 5 US quarts (4.7 L) Recommended Oil Viscosity: API SG, SAE 10W-30 Optional Engine Engine Code: 2.5L I-4 Engine Displacement: 2469 cc (151 ci) Engine Configuration: Inline 4-cylinder, Overhead Valve (OHV) Horsepower Net: 125 hp @ 5200 rpm (approx.) Torque Net: 147 lb-ft @ 3200 rpm (approx.) Fuel System: Throttle Body Injection (TBI) or Multi-point Fuel Injection (MPI) 🔧 Transmission Standard Transmission Type: Manual Transmission Model: AX-5 (2WD and 4WD versions) Gear Ratios: Refer to manual for specific ratios, but typically 5 forward gears + reverse. Clutch Type: Hydraulically actuated diaphragm spring clutch Optional Transmission Type: Automatic Transmission Model: AW-4 (4-speed electronically controlled) Torque Converter Stall Speed: Refer to manual for specifications. Transmission Fluid Type: ATF+3 (or equivalent, consult manual for exact specification) Transmission Fluid Capacity: Approx. 8 US quarts (7.6 L) for AW-4 (dry fill) Transfer Case Standard 4X4 System: Command-Trac NV231 (Part-time, 2WD High, 4WD High, 4WD Low, Neutral) Optional 4X4 System Optional 4X4 System: Selec-Trac NV242 (Full-time, 2WD, 4WD High, 4WD Low, Neutral) Transfer Case Fluid Fluid Type: Mopar Manual Transmission Lubricant (or equivalent, consult manual) Fluid Capacity: Approx. 1.75 US quarts (1.66 L) for NV231/NV242 📐 Dimensions Exterior Lxwxh Dimensions: Approx. 167.5 in (L) x 69.9 in (W) x 64.4 in (H) (1990 Model) Wheelbase Wheelbase: 103.4 inches (2626 mm) Track Width Front Track: 57.5 inches (1460 mm) Rear Track: 57.0 inches (1450 mm) Ground Clearance Ground Clearance: Approx. 8.7 inches (221 mm) for 4x4 models Weights Curb Weight Min...

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Tags: 1990 Car Cars Cherokee XJ Jeep Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Model Code:

Year:

👋 Introduction

Market Position

Vehicle Class:

Compact SUV

Target Audience Manual:

Jeep owners, independent repair shops, automotive enthusiasts.

Competitive Analysis

Competitors Vehicle 1990:

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

Key Features Vehicle

Unibody Construction:

Pioneering unibody construction for an SUV, offering lighter weight and improved ride compared to body-on-frame rivals.

Off Road Capability:

Renowned off-road prowess due to Command-Trac (2WD/4WD) or Selec-Trac (full-time 4WD) transfer cases and robust drivetrain options.

Key Features Manual

Completeness:

Comprehensive, factory-level information essential for accurate diagnosis and repair.

Value Proposition:

Enables cost-effective maintenance and repairs, extending the lifespan and preserving the value of the vehicle.

📋 Manual Details

Identification

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (likely PDF, as implied by 'Repair Manual Software')

📖 Manual Coverage

Systems

Engine Mechanical:

Comprehensive coverage including disassembly, inspection, assembly, and troubleshooting for all engine variants.

Engine Electrical:

Detailed diagrams and troubleshooting for ignition, fuel injection, starting, charging, and emissions control systems.

Transmission Manual:

Service and repair procedures for manual transmissions (e.g., AX-5, BA-10/5).

Transmission Automatic:

Service and repair procedures for automatic transmissions (e.g., AW-4).

Drivetrain 4X4:

Detailed information on transfer case (e.g., NP231), front and rear axle assemblies, and hub operation.

Suspension:

Front and rear suspension components, including leaf springs, shock absorbers, control arms, and steering linkage.

Steering:

Power steering system components, hydraulic pump, steering box/rack, and linkage.

Brakes:

Front disc brakes, rear drum brakes, parking brake system, hydraulic lines, master cylinder, and ABS (if equipped).

Body And Frame:

Body panel removal/installation, door mechanisms, glass, roof, and unibody structural components.

Electrical System:

Complete wiring diagrams, lighting, gauges, interior controls, horn, wipers, and HVAC electrical components.

Heating Ventilation Air Conditioning:

HVAC system components, refrigerant charging, blower motor, heater core, and A/C compressor.

Procedures

Routine Maintenance:

Oil changes, fluid checks and replacements, filter replacements, spark plug service, belt inspection and replacement.

Troubleshooting:

Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems, often with flowcharts.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all vehicle systems.

Diagnostics:

Detailed diagnostic steps, including use of diagnostic tools and interpretation of sensor data (OBD-I for this era).

Rebuilds:

Comprehensive procedures for rebuilding engines, transmissions, transfer cases, and axles.

Technical Depth

Depth Level:

In-depth, professional level suitable for dealership technicians and experienced DIY mechanics.

📊 Manual Specifications

File Properties

File Format:

PDF (typically, for digital versions)

Searchability:

Likely fully text-searchable for quick access to specific topics.

Printability:

Printable pages, allowing for physical reference.

Physical Properties

Page Count Estimated:

1000-2000 pages (typical for a comprehensive factory service manual of this era).

Print Quality:

High-resolution scans/digital reproductions ensuring clarity of diagrams and text.

Binding Type:

N/A (for digital format)

Paper Type:

N/A (for digital format)

⚙️ Engine Specifications

Primary Engine 1

Engine Code:

4.0L I-6 (High Output)

Engine Displacement:

3957 cc (242 ci)

Engine Configuration:

Inline 6-cylinder, Overhead Valve (OHV)

Bore X Stroke:

3.875 in x 3.563 in (98.4 mm x 90.5 mm)

Compression Ratio:

8.8:1

Horsepower Net:

177 hp @ 4750 rpm (approx.)

Torque Net:

220 lb-ft @ 3250 rpm (approx.)

Fuel System:

Multi-point Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with coil packs (later models) or Distributor with Ignition Coil.

Cooling System Capacity:

10.5 US quarts (9.9 L)

Oil Capacity W Filter:

5 US quarts (4.7 L)

Recommended Oil Viscosity:

API SG, SAE 10W-30

Optional Engine

Engine Code:

2.5L I-4

Engine Displacement:

2469 cc (151 ci)

Engine Configuration:

Inline 4-cylinder, Overhead Valve (OHV)

Horsepower Net:

125 hp @ 5200 rpm (approx.)

Torque Net:

147 lb-ft @ 3200 rpm (approx.)

Fuel System:

Throttle Body Injection (TBI) or Multi-point Fuel Injection (MPI)

🔧 Transmission

Standard Transmission

Type:

Manual Transmission

Model:

AX-5 (2WD and 4WD versions)

Gear Ratios:

Refer to manual for specific ratios, but typically 5 forward gears + reverse.

Clutch Type:

Hydraulically actuated diaphragm spring clutch

Optional Transmission

Type:

Automatic Transmission

Model:

AW-4 (4-speed electronically controlled)

Torque Converter Stall Speed:

Refer to manual for specifications.

Transmission Fluid Type:

ATF+3 (or equivalent, consult manual for exact specification)

Transmission Fluid Capacity:

Approx. 8 US quarts (7.6 L) for AW-4 (dry fill)

Transfer Case

Standard 4X4 System:

Command-Trac NV231 (Part-time, 2WD High, 4WD High, 4WD Low, Neutral)

Optional 4X4 System

Optional 4X4 System:

Selec-Trac NV242 (Full-time, 2WD, 4WD High, 4WD Low, Neutral)

Transfer Case Fluid

Fluid Type:

Mopar Manual Transmission Lubricant (or equivalent, consult manual)

Fluid Capacity:

Approx. 1.75 US quarts (1.66 L) for NV231/NV242

📐 Dimensions

Exterior Lxwxh

Dimensions:

Approx. 167.5 in (L) x 69.9 in (W) x 64.4 in (H) (1990 Model)

Wheelbase

Wheelbase:

103.4 inches (2626 mm)

Track Width

Front Track:

57.5 inches (1460 mm)

Rear Track:

57.0 inches (1450 mm)

Ground Clearance

Ground Clearance:

Approx. 8.7 inches (221 mm) for 4x4 models

Weights

Curb Weight Min Max:

Approx. 3,100 - 3,500 lbs (1406 - 1588 kg), depending on configuration

Cargo Volume

Cargo Volume Behind Rear Seat:

Approx. 32.1 cu ft (0.91 m³)

Cargo Volume With Rear Seat Folded:

Approx. 70.2 cu ft (1.99 m³)

Towing Capacity

Max Towing Capacity:

Up to 2,000 lbs (907 kg) or 3,500 lbs (1588 kg) depending on engine and axle ratio (check manual for specifics).

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance Rating 1990:

Likely 3-star (representative for vehicles of this era, specific data for 1990 XJ may vary).

Active Features

Brake System:

Front ventilated discs, rear drums. Optional Anti-lock Braking System (ABS) available on some models.

Traction Control:

Not typically available on 1990 models.

Passive Features

Airbags:

Driver-side airbag standard for 1990.

Seat Belts:

Front and rear seat belts, shoulder belts for front occupants.

Child Safety:

Rear door child safety locks available.

💡 Technology Features

Infotainment

Audio System:

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

Dashboard Controls:

Analog gauges for speedometer, tachometer (on some models), fuel, temperature, oil pressure, and voltmeter. Manual climate controls.

Driver Assistance

ABS Availability:

Optional Anti-lock Braking System (ABS) for rear wheels.

Cruise Control:

Available on higher trim levels.

Connectivity

OBD Standard:

OBD-I (On-Board Diagnostics, First Generation), requiring specialized diagnostic tools and procedures.

🔧 Maintenance

Service Intervals Oil

Oil Change Interval:

Every 3,000 miles (4,800 km) or 3 months, or every 5,000 miles (8,000 km) or 6 months with synthetic oil (refer to manual for definitive recommendation).

Service Intervals Filters

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed. Typically every 30,000 miles (48,000 km).

Fuel Filter Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Cabin Air Filter Replacement:

Not applicable for 1990 models.

Service Intervals Fluids

Coolant Flush Interval:

Every 30,000 miles (48,000 km) or 24 months.

Brake Fluid Flush:

Every 30,000 miles (48,000 km) or 24 months.

Power Steering Fluid Check:

Check every oil change. Flush and replace as needed, typically every 30,000 miles (48,000 km).

Service Intervals Ignition

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs, up to 100,000 miles (160,000 km) for platinum/iridium (if applicable).

Fluid Specifications

Engine Coolant Type:

Mopar Antifreeze/Coolant (or equivalent)

Brake Fluid Type:

DOT 3 Hydraulic Brake Fluid

Power Steering Fluid Type:

ATF+3 (or equivalent, consult manual)

Known Issues Engine

4.0L Common Issues:

Cracked cylinder heads (though less common on 1990 models compared to later years), oil leaks from valve cover and oil pan, lifter tick.

2.5L Common Issues:

Head gasket failures, oil consumption, valve seat issues.

Known Issues Drivetrain

Transfer Case Chain Slap:

NV231 transfer case chain can stretch and cause noise.

Axle Seal Leaks:

Rear axle pinion seal and axle shaft seal leaks are common.

Known Issues Suspension

Leaf Spring Sag:

Rear leaf springs can sag over time, reducing ride height.

Known Issues Electrical

Wiring Harness Issues:

Corrosion and chafing in wiring harnesses, particularly in engine bay and under the vehicle.

Alternator Failure:

Alternators can fail prematurely.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long history of producing rugged, go-anywhere vehicles, originating from military applications (Willys MB).

Model Evolution

Xj Introduction:

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

Xj Updates 1990:

1990 saw the introduction of the more powerful 4.0L High Output inline-six engine as a primary option and the driver-side airbag as standard equipment.

Production

Production Period Xj:

1984-2001 (North America), later in other markets.

Manufacturing Locations:

Primarily Toledo, Ohio, USA.

🏆 Awards & Recognition

Recognitions

Motor Trend SUV Of The Year 1984:

While not for 1990, the XJ was Motor Trend's SUV of the Year upon its introduction in 1984, highlighting its innovative design and capability.

Ratings

Off Road Magazine Ratings:

Consistently praised by off-road publications for its capability and compact size.

Certifications

Emissions Compliance:

Meets U.S. Federal EPA emissions standards for 1990 model year.