Jeep Wrangler 1999 Tj Workshop Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Year: 1999 Codes Chassis Code: TJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Jeep Brand Philosophy:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-Road Vehicle

Jeep Brand Philosophy:

Emphasizes ruggedness, off-road capability, and iconic styling.

Competitive Analysis

Key Competitors:

Toyota 4Runner, Suzuki Samurai, Ford Bronco (early models).

Key Features

Design Philosophy:

Body-on-frame construction, solid axles (front and rear), removable doors and top, iconic seven-slot grille.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Target Audience:

Dealership Technicians

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, overhaul, and troubleshooting for all engine variants.

Engine Management:

Ignition system, fuel injection, emissions control, sensors, actuators, and diagnostic procedures.

Transmission Manual:

NV3550 service, repair, and specifications.

Transmission Automatic:

42RLE service, repair, and specifications (if applicable to 1999 TJ, though less common).

Transfer Case:

NV231 and NV241 service, repair, and troubleshooting.

Drivetrain:

Front and rear axle assemblies, differential service, driveshaft repair, U-joints.

Suspension:

Front and rear suspension systems, coil springs, shocks, control arms, bushings, alignment procedures.

Steering:

Power steering system, steering column, steering gear service and diagnosis.

Brakes:

Front and rear brake systems, disc and drum brake service, ABS diagnosis (if equipped), parking brake.

Electrical System:

Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams.

Body And Chassis:

Body panel removal/installation, structural repairs, interior trim, seats, doors, hardtop/soft top service.

Heating Ventilation Air Conditioning:

HVAC system components, refrigerant handling, diagnosis, and repair.

Restraint Systems:

Airbag system diagnosis and service (if equipped).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, belt inspections, spark plug replacement.

Diagnostics:

System-specific diagnostic charts, trouble code interpretation, step-by-step troubleshooting for common and complex issues.

Repair And Overhaul:

Detailed instructions for component removal, repair, and reassembly, including torque specifications.

Replacement:

Procedures for replacing all major and minor components across all vehicle systems.

Specifications:

Torque values, clearances, fluid capacities, resistance values, diagnostic parameters.

Wiring Diagrams:

Comprehensive, color-coded electrical wiring schematics for all vehicle systems.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical system diagnosis.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable, allowing for quick location of specific topics and procedures.

Print Quality

Image Resolution:

High-resolution for clear diagrams, illustrations, and photos.

Binding Type

Binding Method:

Digital download (PDF), implies no physical binding.

Paper Type

Paper Quality:

N/A (Digital Format)

Completeness

Completeness Level:

Full Workshop Manual, mirroring dealer-issued documentation.

⚙️ Engine Specifications

Primary Engine

Engine Code:

4.0L Inline-6 (OHV)

Engine Displacement:

3957 cc (242 cubic inches)

Bore X Stroke:

3.875 in x 3.570 in (98.4 mm x 90.7 mm)

Compression Ratio:

8.8:1

Performance

Horsepower:

182 hp @ 4600 rpm

Torque:

220 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Engine Variants Covered

Secondary Engine:

2.5L Inline-4 (OHV) (Less common in 1999 TJ, but may be covered)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Manual Transmission Model:

NV3550

Optional

Transmission Type:

4-Speed Automatic Transmission

Automatic Transmission Model:

42RE (More common in earlier TJs, 42RLE emerged later)

Features

Transfer Case:

Command-Trac NV231 (Standard)

Transfer Case Optional:

Selec-Trac NV242 (Less common on TJ)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width:

66.5 inches (1689 mm)

Height:

70.1 inches (1780 mm) (with hardtop)

Ground Clearance:

Approx. 8.3 inches (211 mm)

Weights

Curb Weight:

Approx. 3,300 - 3,500 lbs (1497 - 1588 kg) depending on configuration

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3 out of 5 stars (for 1999 models)

Active Features

Optional on rear wheels, standard on front wheels.

Passive Features

Airbags:

Driver and passenger front airbags.

Seat Belts:

3-point front seat belts, lap belts in rear.

Construction

Frame Type:

Body-on-frame

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, optional CD player. Speaker configuration varied by trim.

Driver Assistance

Cruise Control:

Optional feature on some trims.

Connectivity

Auxiliary Input:

Not typically available in 1999 models; aftermarket solutions common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Engine Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for copper plugs (standard), or 100,000 miles for platinum/iridium (if applicable).

Transmission Fluid Change Manual:

Check level periodically, change as needed or at higher mileages (e.g., 100,000 miles).

Transmission Fluid Change Automatic:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on usage.

Fluid Specifications

Engine Oil Type:

SAE 10W-30 (API SG or higher)

Engine Oil Capacity:

6 US quarts (5.7 Liters) with filter

Coolant Type:

Mopar Antifreeze/Coolant (HOAT) or equivalent (50/50 mix)

Brake Fluid Type:

DOT 3

Power Steering Fluid:

ATF+4 (Automatic Transmission Fluid Type 9602) or Mopar Power Steering Fluid

Manual Transmission Fluid:

GL-3 or GL-4 75W-90 Synthetic Gear Oil (NV3550)

Automatic Transmission Fluid:

ATF+4 (Automatic Transmission Fluid Type 9602) (42RE)

Transfer Case Fluid:

ATF+4 (Automatic Transmission Fluid Type 9602) (NV231)

Axle Differential Fluid Front Rear:

GL-5 75W-90 or 80W-90 Synthetic Gear Oil

Known Issues

Common Problem 1:

Cracked exhaust manifolds (due to high heat and stress on the 4.0L engine).

Common Problem 2:

Leaking valve cover gaskets and oil pan gaskets.

Common Problem 3:

Worn steering components (e.g., tie rod ends, drag link) due to off-road use.

Common Problem 4:

Interior water leaks, particularly around door seals, windshield frame, and hardtop seams.

Common Problem 5:

Transmission synchro issues in manual transmissions (NV3550) with high mileage.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Tracing roots back to the Willys MB Jeep of WWII, embodying off-road prowess and ruggedness.

Model Evolution

Wrangler Lineage:

Successor to the CJ (Civilian Jeep) series, introduced as the YJ in 1987, replaced by the TJ in 1997.

Tj Introduction Year:

Tj Key Changes From Yj:

Return to round headlights, introduction of coil springs on all four wheels (replacing YJ's leaf springs), revised interior and exterior styling.

Production

Production Start Year:

Production End Year:

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Offroad Magazine Awards:

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

Ratings

Jeep Enthusiast Following:

Strong aftermarket support and a dedicated owner community.

Certifications

Emissions Compliance:

Meets Federal EPA and California Air Resources Board (CARB) emissions standards for the model year.