Jeep CHEROKEE XJ Replacement Parts Manual 1991-1993
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Years Covered: 1991, 1992, 1993 Codes Chassis Code: XJ 👋 Introduction Market Position Product Niche: Essential reference for Jeep Cherokee XJ owners and mechanics focusing on parts identification and procurement for the 1991-1993 model years. Competitive Analysis Value Proposition: Provides direct access to OEM part numbers, crucial for sourcing correct components, unlike generic repair manuals which often lack this specificity. Key Features Key Features: Illustrated exploded diagrams, comprehensive part number listings, facilitates accurate repair and parts ordering. 📋 Manual Details Coverage Areas Documentation Type: OEM Parts Manual Primary Purpose: Replacement Parts Identification & Sourcing Page Count Estimated Page Count: Varies by specific edition, typically 300-500 pages Manual Type Manual Type: Parts Catalog / Parts Manual Language Language: English Format Format Description: Illustrated with Exploded Parts Diagrams 📖 Manual Coverage Systems Covered Engine Components: Cylinder head, block, pistons, crankshaft, camshaft, intake/exhaust systems, cooling system, fuel system (injectors, pumps, lines), ignition system components, lubrication system (oil pump, filter housing) Drivetrain Components: Manual and automatic transmissions (AX-4, AW-4, NP231 transfer case), front and rear axles (Dana 30, Chrysler 8.25), driveshafts, U-joints, differentials, hubs, CV joints Suspension Steering Components: Front and rear suspension (leaf springs, coil springs, control arms, track bars, sway bars), steering gear, steering column, power steering pump and components, tie rods, ball joints Braking Components: Front disc brakes, rear drum or disc brakes (depending on configuration), brake master cylinder, brake lines, calipers, pads, rotors, wheel cylinders, brake hardware Electrical Systems: Wiring harnesses, fuses, relays, battery, alternator, starter motor, lighting (headlights, taillights, interior), switches, sensors, engine control module (ECM) components Body Exterior Components: Body panels (fenders, doors, hood, tailgate), bumpers, grille, windows, door handles, mirrors, trim pieces, roof rack components, floor pans, quarter panels Body Interior Components: Seats, dashboard, instrument cluster, steering wheel, center console, door panels, headliner, carpet, climate control vents, seat belts, interior lighting Heating Ventilation Air Conditioning HVAC: Heater core, evaporator, blower motor, A/C compressor, condenser, refrigerant lines, ducting, control modules, actuators Procedures Included Procedure Scope: Disassembly, repair, and assembly guidance through exploded views Parts Identification: Precise identification of all factory-specified replacement parts with part numbers Technical Depth Depth Level: Comprehensive part-level detail for maintenance and repair 📊 Manual Specifications File Format Digital Format Options: Likely available as PDF, potentially as scanned physical document Print Quality Print Quality Description: Dependent on source; OEM quality expected for clarity of diagrams and text Binding Type Binding Type Physical: Typically spiral-bound or perfect-bound for ease of use during repairs Paper Type Paper Type Physical: Durable paper stock suitable for shop environment, often with glossy finish for diagrams ⚙️ Engine Specifications Primary Engine Engine Code Primary: 4.0L Inline-6 OHV (High Output) - AMC 242 Engine Description Primary: Pushrod OHV V6, known for torque and durability. Performance Horsepower 1991 1993 4.0L: Approximately 180-190 hp @ 4700 rpm (varies slightly by year) Torque 1991 1993 4.0L: Approximately 220-230 lb-ft @ 3200 rpm (varies slightly by year) Fuel System Fuel System Type: Multi-port Fuel Injection (MPI) Optional Engine Engine Code Optional: 2.5L Inline-4 OHV (AMC 150) Horsepower 1991 1993 2.5L: Approximately 125 hp @ 4800 rpm Torque 1991 1993 2.5L: Approximately 150 lb-ft @ 2400 rpm 🔧 Transmission Standard Standard Transmission: AX-4 (4-speed Manual) Optional Optional Transmission: AW-4 (4-speed Automatic) Features Transfer Case Standard: New Process (NP) NP231 Command-Trac (Part-time 2-speed) Transfer Case Optional: NP242 Selec-Trac (Full-time 2-speed, optional on some trims) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 166.5 inches (4229 mm) Width: 70.4 inches (1788 mm) Height: 64.7 inches (1643 mm) (varies with roof rack/options) Weights Curb Weight Approx: 3,200 - 3,600 lbs (1451 - 1633 kg) (varies by configuration) Towing Capacity Approx: Up to 5,000 lbs (2268 kg) (with proper equipment and configuration) Cargo Cargo Volume Behind Rear Seat: Approx. 36 cu ft (1019 L) Cargo Volume With Rear Seat Folded: Approx. 70 cu ft (1982 L) 🛡️ Safety Features Ratings NHTSA Rollover Resistance Rating: Likely 3 out of 5 stars (typical for SUVs of this era, requires specific VIN data for definitive rating) Active Features Active Safety Features: Four-wheel drive (4WD) systems (Command-Trac, Selec-Trac), Optional ABS (Anti-lock Braking System) on rear wheels or all four wheels depending on model year and trim. Passive Features Passive Safety Features: Seat belts (front and rear), reinforced body structure, energy-absorbing steering column. 💡 Technology Features Infotainment Infotainment System Features: Basic AM/FM radio, optional cassette player, optional CD player. Analog gauges and controls. Driver Assistance Driver Assistance Features: Limited by modern standards. Optional ABS (Anti-lock Braking System) was the primary advanced safety technology. Connectivity Connectivity Features: No integrated Bluetooth or USB connectivity. Provisions for aftermarket radio installations. 🔧 Maintenance Service Intervals Oil Change Interval Typical: Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (consult specific owner's manual). Transmission Fluid...
Essential reference for Jeep Cherokee XJ owners and mechanics focusing on parts identification and procurement for the 1991-1993 model years.
Competitive Analysis
Value Proposition:
Provides direct access to OEM part numbers, crucial for sourcing correct components, unlike generic repair manuals which often lack this specificity.
Key Features
Key Features:
Illustrated exploded diagrams, comprehensive part number listings, facilitates accurate repair and parts ordering.
📋 Manual Details
Coverage Areas
Documentation Type:
OEM Parts Manual
Primary Purpose:
Replacement Parts Identification & Sourcing
Page Count
Estimated Page Count:
Varies by specific edition, typically 300-500 pages
Manual Type
Manual Type:
Parts Catalog / Parts Manual
Language
Language:
English
Format
Format Description:
Illustrated with Exploded Parts Diagrams
📖 Manual Coverage
Systems Covered
Engine Components:
Cylinder head, block, pistons, crankshaft, camshaft, intake/exhaust systems, cooling system, fuel system (injectors, pumps, lines), ignition system components, lubrication system (oil pump, filter housing)
Drivetrain Components:
Manual and automatic transmissions (AX-4, AW-4, NP231 transfer case), front and rear axles (Dana 30, Chrysler 8.25), driveshafts, U-joints, differentials, hubs, CV joints
Suspension Steering Components:
Front and rear suspension (leaf springs, coil springs, control arms, track bars, sway bars), steering gear, steering column, power steering pump and components, tie rods, ball joints
Braking Components:
Front disc brakes, rear drum or disc brakes (depending on configuration), brake master cylinder, brake lines, calipers, pads, rotors, wheel cylinders, brake hardware
Disassembly, repair, and assembly guidance through exploded views
Parts Identification:
Precise identification of all factory-specified replacement parts with part numbers
Technical Depth
Depth Level:
Comprehensive part-level detail for maintenance and repair
📊 Manual Specifications
File Format
Digital Format Options:
Likely available as PDF, potentially as scanned physical document
Print Quality
Print Quality Description:
Dependent on source; OEM quality expected for clarity of diagrams and text
Binding Type
Binding Type Physical:
Typically spiral-bound or perfect-bound for ease of use during repairs
Paper Type
Paper Type Physical:
Durable paper stock suitable for shop environment, often with glossy finish for diagrams
⚙️ Engine Specifications
Primary Engine
Engine Code Primary:
4.0L Inline-6 OHV (High Output) - AMC 242
Engine Description Primary:
Pushrod OHV V6, known for torque and durability.
Performance
Horsepower 1991 1993 4.0L:
Approximately 180-190 hp @ 4700 rpm (varies slightly by year)
Torque 1991 1993 4.0L:
Approximately 220-230 lb-ft @ 3200 rpm (varies slightly by year)
Fuel System
Fuel System Type:
Multi-port Fuel Injection (MPI)
Optional Engine
Engine Code Optional:
2.5L Inline-4 OHV (AMC 150)
Horsepower 1991 1993 2.5L:
Approximately 125 hp @ 4800 rpm
Torque 1991 1993 2.5L:
Approximately 150 lb-ft @ 2400 rpm
🔧 Transmission
Standard
Standard Transmission:
AX-4 (4-speed Manual)
Optional
Optional Transmission:
AW-4 (4-speed Automatic)
Features
Transfer Case Standard:
New Process (NP) NP231 Command-Trac (Part-time 2-speed)
Transfer Case Optional:
NP242 Selec-Trac (Full-time 2-speed, optional on some trims)
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
166.5 inches (4229 mm)
Width:
70.4 inches (1788 mm)
Height:
64.7 inches (1643 mm) (varies with roof rack/options)
Weights
Curb Weight Approx:
3,200 - 3,600 lbs (1451 - 1633 kg) (varies by configuration)
Towing Capacity Approx:
Up to 5,000 lbs (2268 kg) (with proper equipment and configuration)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 36 cu ft (1019 L)
Cargo Volume With Rear Seat Folded:
Approx. 70 cu ft (1982 L)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance Rating:
Likely 3 out of 5 stars (typical for SUVs of this era, requires specific VIN data for definitive rating)
Active Features
Active Safety Features:
Four-wheel drive (4WD) systems (Command-Trac, Selec-Trac), Optional ABS (Anti-lock Braking System) on rear wheels or all four wheels depending on model year and trim.
Passive Features
Passive Safety Features:
Seat belts (front and rear), reinforced body structure, energy-absorbing steering column.
💡 Technology Features
Infotainment
Infotainment System Features:
Basic AM/FM radio, optional cassette player, optional CD player. Analog gauges and controls.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Optional ABS (Anti-lock Braking System) was the primary advanced safety technology.
Connectivity
Connectivity Features:
No integrated Bluetooth or USB connectivity. Provisions for aftermarket radio installations.
🔧 Maintenance
Service Intervals
Oil Change Interval Typical:
Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (consult specific owner's manual).
Transmission Fluid Change Interval:
Every 30,000-60,000 miles (48,000-96,000 km) for automatic transmission fluid (ATF+4 or equivalent), manual transmission fluid varies.
Fluid Specifications
Engine Oil Type 4.0L:
SAE 10W-30 (API SG or higher) is typical for 1991-1993 models. Consult manual for specific viscosity and API rating.
Coolant Type:
Ethylene glycol-based antifreeze (green) with distilled water, typically a 50/50 mix. Consult manual for specific type and capacity.
Brake Fluid Type:
DOT 3 (typically)
Power Steering Fluid Type:
ATF+4 or specific power steering fluid (consult manual)
Known Issues
Common Issue 1:
Cracked cylinder heads (especially on earlier 4.0L engines, though less prevalent in later XJs like '91-'93 compared to early models, still worth checking).
Common Issue 2:
Leaf spring sag/breakage in the rear suspension due to age and load.
Common Issue 3:
Radiator leaks and coolant system issues, often exacerbated by age.
Common Issue 4:
Interior trim degradation (e.g., headliner sagging, dashboard cracking) due to UV exposure and age.
Common Issue 5:
Rust formation in common areas such as floor pans, rocker panels, and around wheel wells.
Common Issue 6:
Water pump failures and leaks.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Jeep, a brand synonymous with off-road capability and ruggedness, tracing its roots back to WWII military vehicles.
Model Evolution
Model Introduction:
The XJ Cherokee was a groundbreaking vehicle when introduced in 1984, pioneering the compact SUV segment with its unibody construction.
Generation Notes:
The 1991-1993 models represent the second major facelift of the XJ generation, featuring updated interior and exterior styling, including revised dashboards and front fascias.
Production
Production Location:
Toledo, Ohio, USA
Production Period Xj:
1984-2001 (North America)
🏆 Awards & Recognition
Recognitions
Model Recognition 1:
Frequently cited in 'best SUVs of all time' lists for its capability and longevity.
Model Recognition 2:
Praised for its off-road prowess and relatively simple, robust mechanicals.
Certifications
Certification Notes:
Focus is on OEM part specifications, not safety certifications of the manual itself.
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