Jeep Cherokee XJ 1999 Repair Service Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1999 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Target Demographic: Enthusiasts seeking ruggedness, off-road capability, and utility....

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Type: Car

Vendor:

Sku: 438908

Tags: 1999 Car Cars Cherokee XJ Jeep Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee XJ

Year:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Target Demographic:

Enthusiasts seeking ruggedness, off-road capability, and utility.

Competitive Analysis

Competitors 1999:

Ford Explorer, Toyota 4Runner, Chevrolet Blazer, Nissan Pathfinder

Key Features Vehicle

Body On Frame:

Yes (Industry standard for robust off-road performance)

Solid Axles:

Yes (Front and Rear, contributing to articulation and durability)

Off Road Capability:

Renowned for its off-road prowess, especially with 4WD systems.

Key Features Manual

Completeness:

Covers all aspects of vehicle repair and maintenance for the specified model year.

Detail Level:

Provides in-depth technical information suitable for professional technicians.

📋 Manual Details

Coverage Areas

Manual Type:

Repair Service Manual

Language:

English

Format:

PDF Download

Audience:

Professional Technicians and Advanced DIY Enthusiasts

📖 Manual Coverage

Systems Covered

Engine:

2.5L (150 CID) Inline-4 "AMC 150" Engine

Transmission:

42RLE 4-Speed Automatic Transmission

Transfer Case:

Selec-Trac NV242 Command-Trac NV231

Drivetrain:

Front and Rear Axles (Dana 30 Front, Dana 35 Rear)

Suspension:

Front Leaf Spring Solid Axle, Rear Leaf Spring Solid Axle

Brakes:

Front Disc Brakes, Rear Drum Brakes (with ABS option)

Steering:

Power Steering System

Electrical:

Starting and Charging System

Fuel System:

Fuel Tank, Pump, Lines, and Injectors

Cooling System:

Radiator, Water Pump, Thermostat, Fan Clutch

Exhaust System:

Exhaust Manifold, Catalytic Converter, Muffler

Body:

Body Panels, Doors, Hood, Liftgate, Bumpers

Interior:

Seats, Dashboard, Trim Panels, Carpeting

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC)

Wheels Tires:

Wheel specifications, tire pressure recommendations, lug nut torque.

Engine Cooling System:

Radiator, fan clutch, water pump, thermostat, coolant hoses, and heater core.

Exhaust System Components:

Exhaust manifold(s), catalytic converter, muffler, and tailpipe.

Procedures Included

Maintenance:

Scheduled Maintenance Intervals (Oil Changes, Filter Replacements, etc.)

Troubleshooting:

Diagnostic Procedures for Common Problems

Repair:

Step-by-Step Repair Instructions for All Major Systems

Disassembly Reassembly:

Detailed Disassembly and Reassembly Procedures

Specifications:

Torque Specifications for Critical Fasteners

Wiring Diagrams:

Comprehensive Electrical Wiring Diagrams

Diagnostic Codes:

OBD-II Diagnostic Trouble Codes (DTCs) and Explanations

Wheel Alignment:

Specifications and procedures for wheel alignment.

Lubrication:

Chassis lubrication points and intervals.

Chassis Alignment:

Specifications for front and rear axle alignment, caster, camber, and toe-in.

Wheel Bolt Pattern:

5 x 4.5 inches (5 x 114.3 mm)

Tire Size Recommendations:

Common sizes include P225/75R15, P235/75R15, and P235/70R16 (check owner's manual for specific trim and options).

Technical Depth

Depth:

Comprehensive Engine Overhaul, Transmission Rebuilding, Suspension Upgrades, Electrical System Diagnosis, Body Repair

Engine Management:

Detailed explanation of the Powertrain Control Module (PCM) operation, sensor functions, and diagnostic procedures.

Fuel Injection Diagnosis:

Troubleshooting and repair procedures for the fuel injection system, including injector testing and fuel pressure checks.

Brake System Repair:

Detailed instructions for brake pad replacement, caliper service, drum brake adjustment, and ABS system troubleshooting.

Suspension And Steering Overhaul:

Comprehensive guidance on servicing and replacing steering and suspension components, including alignment adjustments.

HVAC System Service:

Diagnosing and repairing the heating, ventilation, and air conditioning system, including refrigerant handling and component replacement.

Body And Interior Repair:

Procedures for body panel repair, door and liftgate adjustments, and interior trim removal and installation.

Diagnostics:

Extensive diagnostic flowcharts and troubleshooting guides for all major vehicle systems.

📊 Manual Specifications

File Specifications

File Format:

Searchable Text:

Printable:

Page Count:

Est. 1000+ pages (typical for comprehensive factory service manuals)

Print Quality:

High-Resolution Scans

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4.0L "Power Tech" (AMC 242)

Configuration:

Inline-6, Overhead Valve (OHV)

Displacement Liters:

Displacement Cid:

Bore X Stroke:

3.875 in x 3.562 in (98.4 mm x 90.5 mm)

Compression Ratio:

8.8:1

Horsepower Hp:

190 @ 4400 RPM

Torque Lb Ft:

225 @ 3200 RPM

Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) style ignition (later models)

Secondary Engine

Engine Code:

2.5L (AMC 150)

Configuration:

Inline-4, Overhead Valve (OHV)

Displacement Liters:

Displacement Cid:

Horsepower Hp:

125 @ 4800 RPM

Torque Lb Ft:

150 @ 3600 RPM

Fuel System

Fuel Type:

Unleaded Gasoline

Engine Oil

Oil Type 4.0L:

API SN/SP 5W-30 Synthetic Motor Oil Recommended

Oil Capacity 4.0L:

5.0 US quarts (4.7 Liters) with filter

Oil Type 2.5L:

API SN/SP 5W-30 Synthetic Motor Oil Recommended

Oil Capacity 2.5L:

5.0 US quarts (4.7 Liters) with filter

🔧 Transmission

Automatic

Model:

42RLE

Type:

4-Speed Automatic Overdrive

Fluid Type:

ATF+3 (Chrysler material number 05010058AA) or equivalent

Fluid Capacity:

Approx. 9.0 US quarts (8.5 Liters)

Manual

Model:

AX-15

Type:

5-Speed Manual

Fluid Type:

GL-3 or GL-4 SAE 75W-90 Gear Oil

Fluid Capacity:

Approx. 2.4 US quarts (2.3 Liters)

📐 Dimensions

Exterior

Length:

171.5 in (4356 mm)

Width:

70.5 in (1791 mm)

Height:

65.1 in (1654 mm)

Wheelbase:

101.4 in (2576 mm)

Ground Clearance:

Approx. 8.7 in (221 mm) (stock)

Weights

Curb Weight Start:

Approx. 3,300 lbs (1497 kg)

Curb Weight End:

Approx. 3,800 lbs (1724 kg) (depending on configuration)

Gross Vehicle Weight Rating Gvw:

Approx. 4,800 lbs (2177 kg)

🛡️ Safety Features

Ratings

NHTSA Front Driver Side Impact:

Not extensively rated by NHTSA in the modern sense, but generally considered robust for its era.

IIHS Side Impact:

Not rated by IIHS for this specific year.

Active Features

Optional Anti-lock Braking System (ABS) on front wheels, and rear wheels for some models.

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Seatbelts:

Front and Rear Seat Belts with Pretensioners

Rollover Protection:

Reinforced unibody structure designed for rollover resistance (body-on-frame structure also contributes).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM Stereo with Cassette Player and Optional CD Player. Basic speaker configuration.

Driver Assistance

Optional Anti-lock Braking System (ABS) available on some models.

Connectivity

Connectivity Features:

Limited by 1999 standards; typically includes power windows and locks on higher trims. No Bluetooth or integrated navigation available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first, depending on driving conditions. Synthetic oil can extend this.

Tire Rotation Interval:

Every 5,000-7,500 miles (8,000-12,000 km)

Coolant Flush Interval:

Every 30,000 miles (48,000 km) or 2 years

Transmission Fluid Change Interval Auto:

Every 30,000-60,000 miles (48,000-96,000 km), check condition.

Transmission Fluid Change Interval Manual:

Every 50,000-100,000 miles (80,000-160,000 km), check condition.

Fluid Specifications

Brake Fluid:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent DEXRON III/MERCON ATF

Transfer Case Fluid:

ATF+4 (Chrysler material number 68045620AA) or equivalent for NV242; ATF+3 for NV231 (check manual for exact spec).

Coolant:

50/50 mixture of Mopar Antifreeze/Coolant (MS-7170) and distilled water.

Known Issues

Common Problems:

Cracked cylinder heads (especially early 4.0L models, though less common in later XJs), oil filter adapter housing leaks, rear main seal leaks, dashboard cracking, sway bar end link wear, rear main bearing cap walk (4.0L).

Electrical Gremlins:

Intermittent electrical issues, often related to grounds, wiring harness degradation, or failing sensors.

Cooling System Issues:

Water pump failure, radiator leaks, and thermostat housing leaks can occur with age.

Suspension Wear:

Leaf spring sag, worn bushings, and track bar wear are common due to off-road use and age.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep, a brand with deep roots in military and off-road vehicles since WWII, known for its ruggedness and capability.

Model Evolution

Xj Introduction:

The XJ Cherokee was a revolutionary vehicle, introducing the unibody construction to SUVs for weight savings and a more car-like ride while retaining off-road capability.

Xj Generations:

First generation (1984-2001), with the 1999 model being part of the later, refined years of the XJ platform.

Xj Unibody Innovation:

Pioneered unibody construction in SUVs, offering a lighter and more refined experience compared to body-on-frame competitors of the time, without compromising off-road capability.

Production

Manufacturing Location:

Toledo, Ohio, USA

Production Years:

1984-2001