Jeep Cherokee XJ 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1999 Codes Chassis Code: XJ Engine Codes: 4.0L (AMC 242), 2.5L (AMC 150) 👋 Introduction Market Position Segment: Compact SUV...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee XJ

Year:

Codes

Chassis Code:

Engine Codes:

4.0L (AMC 242), 2.5L (AMC 150)

👋 Introduction

Market Position

Segment:

Compact SUV / Off-road oriented SUV

Target Audience:

Off-road enthusiasts, DIY mechanics, owners seeking in-depth vehicle knowledge

Competitive Analysis

Competitors 1999:

Toyota RAV4, Honda CR-V, Ford Explorer, Nissan Pathfinder

Unique Selling Proposition:

Renowned off-road capability, legendary inline-six engine, robust unibody construction

Key Features

Iconic Engine:

4.0L "Power-Tech" Inline-6 (AMC 242)

Body Style:

2-door and 4-door (Sport Utility Vehicle)

Drivetrain Options:

Part-time 4WD (Command-Trac), Full-time 4WD (Selec-Trac)

Suspension Design:

Front solid axle, rear leaf springs (known for durability and articulation)

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Suspension:

Steering:

Brakes:

Electrical System:

Body And Chassis:

HVAC:

Body Electrical:

Diagnostic Troubleshooting:

Maintenance Procedures:

Wiring Diagrams:

Page Count

Estimated Pages:

Approx. 2000+

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, assembly, disassembly, component testing, diagnostics

Engine Performance:

Fuel injection, ignition system, emissions control, engine management diagnostics

Transmission Manual:

NV3550, AX-15 (if applicable to '99 spec, though AX-15 phased out), rebuild procedures, component identification

Transmission Automatic:

AW4 (42RE), rebuild procedures, hydraulic control systems, electronic diagnostics

Transfer Case:

NP231, NP242 (Selec-Trac), disassembly, assembly, maintenance, repair

Axles And Differentials:

Dana 30 (front), Chrysler 8.25 (rear), Dana 44 (optional rear), bearing preloads, gear backlash, fluid specifications

Suspension Front:

Solid beam axle, leaf springs, shock absorbers, steering linkage, alignment specifications

Suspension Rear:

Leaf springs, shock absorbers, axle articulation

Steering System:

Power steering pump, steering gear, tie rods, drag links, hydraulic pressure tests

Brake System:

Front disc brakes, rear drum brakes, ABS (if equipped), brake fluid specifications, bleeding procedures, caliper/cylinder overhaul

Fuel System:

Fuel pump, injectors, fuel pressure regulator, fuel filter replacement, EVAP system

Cooling System:

Radiator, water pump, thermostat, coolant specifications, flush and fill procedures

Exhaust System:

Muffler, catalytic converter, pipe routing, hanger replacement

HVAC System:

Air conditioning compressor, condenser, evaporator, refrigerant, heater core, blower motor, controls

Interior Electrical:

Dashboard instruments, lighting, power windows, power locks, seat controls, audio system

Exterior Electrical:

Headlights, taillights, turn signals, mirrors, wiper system, horn

Body And Frame:

Unibody construction, door mechanisms, tailgate, panel replacement, rust prevention

Safety Systems:

Seat belts, airbags (if equipped), child seat anchors

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations

Major Repairs:

Engine rebuilds, transmission overhauls, axle servicing

Troubleshooting:

System-specific diagnostic charts, common fault identification, symptom-based troubleshooting

Component Replacement:

Detailed step-by-step instructions for replacing virtually all major and minor components

Diagnostic Testing:

Specifications for electrical tests, pressure tests, vacuum tests, resistance checks

Tune Up Procedures:

Spark plug replacement, ignition timing, fuel system cleaning

Calibration And Adjustment:

Wheel alignment, parking brake adjustment, throttle cable adjustment

Body Work And Refinishing:

Panel alignment, trim piece removal and installation, basic body repair guidance

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete overhauls and advanced diagnostics

Detail Level:

Factory-level detail with exploded views, torque specifications, and diagnostic flowcharts

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Printability:

Printable pages

Resolution:

High-resolution for clarity of diagrams and text

Print Quality

Quality:

N/A (Digital PDF)

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1:

4.0L (3956 cc) Inline-6 OHV

Engine 1 Bore X Stroke:

3.875 in x 2.875 in (98.4 mm x 73.0 mm)

Engine 1 Compression Ratio:

8.8:1

Engine 1 Horsepower:

190 hp @ 4600 rpm

Engine 1 Torque:

225 lb-ft @ 3200 rpm

Engine 1 Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Engine 1 Ignition System:

Distributorless Ignition System (DIS) with distributorless coil pack

Engine 1 Block Material:

Cast Iron

Engine 1 Head Material:

Cast Iron

Engine 1 Oil Capacity:

5 quarts (4.7 liters) with filter

Engine 1 Recommended Oil:

API SJ, SAE 10W-30

Optional Engine

Engine 2:

2.5L (2492 cc) Inline-4 OHV (AMC 150)

Engine 2 Horsepower:

125 hp @ 4800 rpm

Engine 2 Torque:

145 lb-ft @ 3200 rpm

Engine 2 Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

🔧 Transmission

Standard

Transmission 1:

4-speed Automatic (42RE / AW4)

Optional

Transmission 2:

5-speed Manual (NV3550)

Features

Overdrive Gears:

Yes (4th gear in auto, 5th gear in manual)

Transfer Case Options:

Command-Trac (231), Selec-Trac (242)

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (Chrysler specification, previously ATF+3 or Dexron III)

Manual Transmission Fluid:

NV3550: SAE 75W-90 synthetic gear oil (API GL-4 or GL-5)

📐 Dimensions

Exterior

Length:

169.4 in (4303 mm)

Width:

70.0 in (1778 mm)

Height:

63.7 in (1618 mm)

Wheelbase:

101.4 in (2576 mm)

Ground Clearance:

Approx. 8.1-9.1 inches (20.6-23.1 cm) depending on tire/suspension

Weights

Curb Weight Approx:

3,400 - 3,600 lbs (1542 - 1633 kg)

Gross Vehicle Weight Rating Gvw:

Approx. 4,850 lbs (2200 kg)

Towing Capacity:

Up to 2,000 lbs (907 kg) for 4-cylinder, 3,500 lbs (1588 kg) for 6-cylinder

Dimensions

Wheel Bolt Pattern:

5x4.5 inches (5x114.3 mm)

Standard Tire Size:

225/75R15

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3-star (for 4-door models)

Active Features

Optional Anti-lock Braking System (ABS) on all four wheels

Traction Control:

Not commonly equipped on 1999 models

Passive Features

Airbags:

Driver and passenger front airbags

Seat Belts:

Three-point seat belts in front and rear seating positions

Child Seat Anchors:

Lower Anchors and Tethers for Children (LATCH) system not standard on this generation.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player. Optional CD player. Speaker configuration varied by trim.

Display:

Analog gauges and dashboard indicator lights. No central display screen.

Driver Assistance

Cruise Control:

Available on most trims.

Parking Sensors:

Not available.

Connectivity

Bluetooth:

Not available.

Usb Ports:

Not available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 7,500 miles (5,000 to 12,000 km) depending on oil type and driving conditions.

Transmission Fluid Change:

Every 30,000 to 60,000 miles (48,000 to 96,000 km) for automatic transmissions.

Coolant Flush Interval:

Every 30,000 to 60,000 miles (48,000 to 96,000 km) or 2-3 years.

Spark Plug Replacement:

4.0L I6: Every 100,000 miles (160,000 km) with platinum plugs. 2.5L I4: Every 30,000 miles (48,000 km) with copper plugs.

Transfer Case Fluid Change:

Every 30,000 to 60,000 miles (48,000 to 96,000 km).

Fluid Specifications

Engine Coolant:

50/50 mix of Mopar Antifreeze/Coolant (MS-7170) and distilled water, or equivalent HOAT coolant.

Brake Fluid:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or Dexron III ATF

Differential Fluid Front:

Dana 30: SAE 80W-90 GL-5 gear oil. Add friction modifier if limited-slip. Capacity: ~1.5 quarts.

Differential Fluid Rear:

Chrysler 8.25: SAE 80W-90 GL-5 gear oil. Capacity: ~2.25 quarts. Dana 44: SAE 80W-90 GL-5 gear oil. Add friction modifier if limited-slip. Capacity: ~2.75 quarts.

Known Issues

Common Issues Engine:

Cracked cylinder heads (less common on later 4.0L engines), oil filter adapter leaks, intake manifold gasket leaks.

Common Issues Transmission:

AW4 transmission cooler line leaks, solenoids in automatic transmissions.

Common Issues Suspension:

Leaf spring sag, worn bushings, track bar wear (on some models), steering box play.

Common Issues Electrical:

Window motor failures, headlight switch issues, grounds in the wiring harness, CPS (Crankshaft Position Sensor) failure on 4.0L.

Common Issues Body:

Rust, particularly in rocker panels, rear quarter panels, and around wheel wells. Door seal deterioration.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's long history of producing rugged, off-road capable vehicles dating back to WWII.

Model Evolution

Xj Introduction:

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

Generation:

The 1999 model is part of the second generation (1997-2001) of the XJ Cherokee, featuring updated styling and interior.

1999 Updates:

Minor updates in 1999 included revised interior trim and potentially minor powertrain tweaks.

Production

Manufacturing Location:

Toledo, Ohio, USA

Production Years:

1984 - 2001 (North America)

🏆 Awards & Recognition

Recognitions

Off Road Reputation:

Consistently praised for its off-road prowess and durability by automotive journalists and enthusiasts.

Value Proposition:

Often cited as a great value SUV for its blend of capability, reliability, and relatively affordable price.