1991 Jeep Wrangler Service and Repair Manual

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Covers all 1991 Wrangler trims — Renegade Sport Utility 2-Door, Islander Sport Utility 2-Door, Sahara Sport Utility 2-Door +2 more ·
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This factory service and repair manual is specific to the 1991 Jeep Wrangler, which was offered with two engines and five trims. Because it is matched to the 1991 model year, the specifications and procedures correspond to your exact engine and trim.

Engines

  • 2.5L I4 (150 cu in), OHV
  • 4.0L I6 (242 cu in), OHV

Trims

  • Base
  • Islander
  • Renegade
  • S
  • Sahara

Known issues on the 1991 Wrangler. Two recalls are on federal record for this model year: an ignition-switch fault that can allow an unintended start while the manual transmission is left in a drive gear, and an equipment fault in which the cockpit could strike and injure persons outside the vehicle. Owners have filed 100 complaints and Jeep has issued 10 technical service bulletins for the year.

From a routine service interval to an ignition-switch fault or a hard-to-trace wiring problem, it keeps you on the factory procedure and the correct specification for your specific 1991 Wrangler.

NHTSA #93V08300011/05/1993Component: ELECTRICAL SYSTEM:IGNITION:SWITCH

SALT CORROSION PRODUCTS BETWEEN THE STARTER SOLENOID WIRE AND THE ADJACENT BATTERY FEED IN THE BULKHEAD CONNECTOR MAY SHORT THESE CONNECTIONS, CAUSING THE CIRCUIT TO BYPASS THE IGNITION KEY CONTROL OF

Consequence

THE UNINTENDED START OF A VEHICLE WITH A MANUALTRANSMISSION LEFT IN A DRIVE GEAR CAN RESULT IN A RUN

Remedy

THE STARTER SOLENOID WIRING WILL BE SEPARATED FROM THE BATTERY FEED WIRE BY RELOCATING IT WITHIN THE

NHTSA #04E04100007/06/2004Component: EQUIPMENT

BESTOP AFTERMARKET REAR SHELL ROOF RACKS,MANUFACTURED BETWEEN APRIL 27 AND MAY 20, 2004, DESIGNED FOR USE WITH THE BESTOP HARDTOP MADE FOR THE 1986-1995 AND 1997-2003 JEEP WRANGLER. THE COCKPIT COVE

Consequence

SHOULD THIS OCCUR, THE COCKPIT COULD CAUSE INJURY BY STRIKING PERSONS OUTSIDE THE VEHICLE OR COULD B

Remedy

BESTOP WILL NOTIFY ITS CUSTOMERS AND PROVIDE A REPAIR KIT AND INSTALLATION INSTRUCTIONS FREE OF CHAR

TSB #10175510

DIPAP Requirements - Addition of Jeep Wrangler (JL/JK) and Jeep Gladiator (JT) Hard Top and Targa Top Panel Replacements - All Dealers (Rev. A)

TSB #618049

SUBJECT REGARDING WIRE SPLICE REPAIRS. *SB

TSB #609995

THIS BULLETIN PROVIDES A REVISED WIRE SPLICE PROCEDURE AND RELATED PARTS. *TT

TSB #6088786

CONCERNS WITH ENGINE COOLANT USAGE. *NLM

TSB #600862

INFORMATION ON INSTALLATION OF RADIO TRANSMITTING EQUIPMENT. *AK

TSB #603108

OUTER EXHAUST MANIFOLD STUDS MAY FATIGUE/BREAK. *AK

TSB #602327

THE OUTER EXHAUST MANIFOLD STUDS MAY FATIGUE AND BREAK. *YC

TSB #54225

RECALL NOTIFICATION AND PROCEDURE ON CATALYTIC CONVETER AND CARBURETOR. *YC

Showing the 8 most recent of 10 technical service bulletins on file with NHTSA.

20040115Component: PARKING BRAKE:CONVENTIONALCrash reported

1991 JEEP WRANGLER PARKING BRAKE DISENGAGED AND VEHICLE ROLLED DOWN A HILL AND HIT A CAR. *MR THE CONSUMER REQUESTED TO BE REIMBURSED FOR THE DAMAGES THAT WERE CAUSED. *SC

20030404Component: PARKING BRAKE:CONVENTIONALCrash reported

NAR 04/07/2003 MR WHEN THE CONSUMER EXITED THE VEHICLE, IT ROLLED BACK, RAPIDLY ACCELERATED HIT A CURB AND BECAME AIRBORNE AND DISAPPEARED OVER THE CLIFF. THE CONSUMER BELIVEVED THE RECALL DEFECT

19960808Component: PARKING BRAKECrash reported

TRUCK WAS PARKED WITH EMERGENCY PARKING BRAKE ON, JUMPED OUT OF GEAR AND ROLLED DOWN DRIVE INTO THE STREET AND HIT PARKED CAR, NO ONE WAS INJURY. PLEASE DESCRIBE *AK.

19960808Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported

TRUCK WAS PARKED WITH EMERGENCY PARKING BRAKE ON, JUMPED OUT OF GEAR AND ROLLED DOWN DRIVE INTO THE STREET AND HIT PARKED CAR, NO ONE WAS INJURY. PLEASE DESCRIBE *AK.

19951228Component: PARKING BRAKE:CONVENTIONALCrash reported

EMERGENCY BRAKE RELEASED AFTER 15-20 SECONDS, CAUSING AN ACCIDENT. *SD

Showing the 5 most serious of 100 complaints filed with NHTSA.

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