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Jeep Wrangler 1999 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 1999 Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV, Off-Road Vehicle Target Audience: Off-road enthusiasts, adventure seekers, individuals requiring a durable and capable vehicle. Competitive Analysis Key Competitors 1999: Toyota 4Runner, Ford Bronco (last year), Nissan Pathfinder, Chevrolet Blazer. Key Features Off Road Capability: Solid front and rear axles, robust 4x4 system (Command-Trac NV231 transfer case), high ground clearance, short wheelbase. Design: Iconic Jeep styling, removable doors and top (full doors or half doors, soft top or hardtop options). 📋 Manual Details Coverage Areas Primary Coverage: 1999 Jeep Wrangler (TJ Generation) Page Count Estimated Pages: 1000+ Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, diagnosis, repair, lubrication system, cooling system, fuel system, exhaust system, emissions control. Transmission Drivetrain: Manual transmission (AX-5, NV3550), automatic transmission (30RH), transfer case (NP231), drivelines, axles, differentials, propeller shafts, U-joints. Brakes: Front disc brakes, rear drum brakes (standard), ABS system (if equipped), hydraulic system, parking brake, bleeding procedures. Suspension Steering: Front solid axle (Dana 30), rear solid axle (Dana 35c), coil springs, shock absorbers, steering gear, power steering system, alignment specifications. Electrical: Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system, instrumentation, fuses, relays, wiring diagrams, body control modules. Body Chassis: Frame, body panels, doors, hood, windshield, rear gate, interior trim, seats, convertible top, bumpers, corrosion protection. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection and replacement, brake pad replacement. Diagnostic Procedures: Troubleshooting charts for common drivability issues, electrical faults, cooling system problems, brake issues, using diagnostic tools. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems. Calibration Adjustment: Wheel alignment, throttle linkage adjustment, parking brake adjustment, headlight aiming. Technical Depth Depth: Comprehensive: Covers routine maintenance, diagnostics, complete component overhauls, and major system repairs. Suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Resolution: High resolution, clear diagrams and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Search: Searchable text for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Code Base: 4.0L Inline-6 (VIN Z) Engine Displacement Base: 3957 cc (241.4 cu in) Engine Block Material Base: Cast Iron Engine Head Material Base: Cast Iron Engine Configuration Base: Inline 6-cylinder, overhead valves (OHV) Bore X Stroke Base: 98.4 mm x 86.7 mm (3.87 in x 3.41 in) Compression Ratio Base: 8.8:1 Horsepower Base: 182 hp @ 4600 rpm Torque Base: 220 lb-ft @ 3200 rpm Fuel System Base: Sequential Multiport Electronic Fuel Injection (MPI) Ignition System Base: Distributorless Ignition System (DIS) with coil-on-plug (COP) technology from 1999 onwards. Emissions Control Base: Catalytic converter, Oxygen sensors, EGR (Exhaust Gas Recirculation) system. Optional Engine Engine Code Optional: 2.5L Inline-4 (VIN T) Engine Displacement Optional: 2507 cc (153 cu in) Horsepower Optional: 114 hp @ 4700 rpm Torque Optional: 145 lb-ft @ 3500 rpm Fuel System Optional: Multiport Fuel Injection (MPI) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual (AX-5, or NV3550 for later 4.0L models) Gear Ratios Ax5: AX-5: 1st: 3.97, 2nd: 2.32, 3rd: 1.54, 4th: 1.00, 5th: 0.85 Gear Ratios Nv3550: NV3550: 1st: 4.01, 2nd: 2.32, 3rd: 1.40, 4th: 1.00, 5th: 0.78 Optional Transmission Type Optional: 3-Speed Automatic (30RH) Features Transfer Case: New Process NP231 Command-Trac (Part-time, 2-speed with 2.72:1 low range) Fluid Specifications Manual Transmission Fluid Ax5: API GL-5, SAE 75W-90 Gear Oil (or specific Chrysler fluid) Automatic Transmission Fluid: ATF+4 (Mopar) Fluid Capacities Manual Transmission Capacity: Approx. 2.0 L (2.1 qts) Automatic Transmission Capacity: Approx. 7.0 L (7.4 qts) 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 151.4 inches (3845 mm) Width: 66.5 inches (1689 mm) Height: 71.3 inches (1811 mm) (with hardtop) Ground Clearance: Approx. 8.5 inches (216 mm) Weights Curb Weight: Approx. 3400 - 3700 lbs (1542 - 1678 kg) depending on configuration Gross Vehicle Weight Rating: Approx. 4700 lbs (2132 kg) Towing Capacity: 2000 lbs (907 kg) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 2-star rating (typical for this era and vehicle type) Active Features Braking System: Front ventilated disc, rear drum. Optional Anti-lock Braking System (ABS) on rear wheels only. Passive Features Airbags: Driver and passenger front airbags. Seat Belts: Three-point front seat belts with pretensioners, lap belts for rear passengers. Roll Cage: Integrated roll cage structure for enhanced occupant protection in rollovers. 💡 Technology Features Infotainment Radio Options: AM/FM stereo with cassette player, optional CD player. Basic speaker systems. Driver Assistance ABS: Optional rear-wheel ABS. Connectivity Connectivity Features: Limited by era; primarily focused on basic functionality. No Bluetooth or USB connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles (4,800...
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Jeep Wrangler 1999 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Year:
1999
Codes
Chassis Code:
TJ
👋 Introduction
Market Position
Segment:
Compact SUV, Off-Road Vehicle
Target Audience:
Off-road enthusiasts, adventure seekers, individuals requiring a durable and capable vehicle.
Competitive Analysis
Key Competitors 1999:
Toyota 4Runner, Ford Bronco (last year), Nissan Pathfinder, Chevrolet Blazer.
Key Features
Off Road Capability:
Solid front and rear axles, robust 4x4 system (Command-Trac NV231 transfer case), high ground clearance, short wheelbase.
Design:
Iconic Jeep styling, removable doors and top (full doors or half doors, soft top or hardtop options).
📋 Manual Details
Coverage Areas
Primary Coverage:
1999 Jeep Wrangler (TJ Generation)
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, diagnosis, repair, lubrication system, cooling system, fuel system, exhaust system, emissions control.
Transmission Drivetrain:
Manual transmission (AX-5, NV3550), automatic transmission (30RH), transfer case (NP231), drivelines, axles, differentials, propeller shafts, U-joints.
Brakes:
Front disc brakes, rear drum brakes (standard), ABS system (if equipped), hydraulic system, parking brake, bleeding procedures.
Suspension Steering:
Front solid axle (Dana 30), rear solid axle (Dana 35c), coil springs, shock absorbers, steering gear, power steering system, alignment specifications.
Electrical:
Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system, instrumentation, fuses, relays, wiring diagrams, body control modules.
Body Chassis:
Frame, body panels, doors, hood, windshield, rear gate, interior trim, seats, convertible top, bumpers, corrosion protection.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection and replacement, brake pad replacement.
Diagnostic Procedures:
Troubleshooting charts for common drivability issues, electrical faults, cooling system problems, brake issues, using diagnostic tools.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems.
Calibration Adjustment:
Wheel alignment, throttle linkage adjustment, parking brake adjustment, headlight aiming.
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, diagnostics, complete component overhauls, and major system repairs. Suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Image Resolution:
High resolution, clear diagrams and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Text Search:
Searchable text for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
4.0L Inline-6 (VIN Z)
Engine Displacement Base:
3957 cc (241.4 cu in)
Engine Block Material Base:
Cast Iron
Engine Head Material Base:
Cast Iron
Engine Configuration Base:
Inline 6-cylinder, overhead valves (OHV)
Bore X Stroke Base:
98.4 mm x 86.7 mm (3.87 in x 3.41 in)
Compression Ratio Base:
8.8:1
Horsepower Base:
182 hp @ 4600 rpm
Torque Base:
220 lb-ft @ 3200 rpm
Fuel System Base:
Sequential Multiport Electronic Fuel Injection (MPI)
Ignition System Base:
Distributorless Ignition System (DIS) with coil-on-plug (COP) technology from 1999 onwards.
Emissions Control Base:
Catalytic converter, Oxygen sensors, EGR (Exhaust Gas Recirculation) system.
Optional Engine
Engine Code Optional:
2.5L Inline-4 (VIN T)
Engine Displacement Optional:
2507 cc (153 cu in)
Horsepower Optional:
114 hp @ 4700 rpm
Torque Optional:
145 lb-ft @ 3500 rpm
Fuel System Optional:
Multiport Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual (AX-5, or NV3550 for later 4.0L models)
Gear Ratios Ax5:
AX-5: 1st: 3.97, 2nd: 2.32, 3rd: 1.54, 4th: 1.00, 5th: 0.85
Gear Ratios Nv3550:
NV3550: 1st: 4.01, 2nd: 2.32, 3rd: 1.40, 4th: 1.00, 5th: 0.78
Optional
Transmission Type Optional:
3-Speed Automatic (30RH)
Features
Transfer Case:
New Process NP231 Command-Trac (Part-time, 2-speed with 2.72:1 low range)
Fluid Specifications
Manual Transmission Fluid Ax5:
API GL-5, SAE 75W-90 Gear Oil (or specific Chrysler fluid)
Automatic Transmission Fluid:
ATF+4 (Mopar)
Fluid Capacities
Manual Transmission Capacity:
Approx. 2.0 L (2.1 qts)
Automatic Transmission Capacity:
Approx. 7.0 L (7.4 qts)
📐 Dimensions
Exterior
Wheelbase:
93.4 inches (2372 mm)
Length:
151.4 inches (3845 mm)
Width:
66.5 inches (1689 mm)
Height:
71.3 inches (1811 mm) (with hardtop)
Ground Clearance:
Approx. 8.5 inches (216 mm)
Weights
Curb Weight:
Approx. 3400 - 3700 lbs (1542 - 1678 kg) depending on configuration
Gross Vehicle Weight Rating:
Approx. 4700 lbs (2132 kg)
Towing Capacity:
2000 lbs (907 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
2-star rating (typical for this era and vehicle type)
Active Features
Braking System:
Front ventilated disc, rear drum. Optional Anti-lock Braking System (ABS) on rear wheels only.
Passive Features
Airbags:
Driver and passenger front airbags.
Seat Belts:
Three-point front seat belts with pretensioners, lap belts for rear passengers.
Roll Cage:
Integrated roll cage structure for enhanced occupant protection in rollovers.
💡 Technology Features
Infotainment
Radio Options:
AM/FM stereo with cassette player, optional CD player. Basic speaker systems.
Driver Assistance
ABS:
Optional rear-wheel ABS.
Connectivity
Connectivity Features:
Limited by era; primarily focused on basic functionality. No Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months. Check manual for synthetic oil recommendations and extended intervals.
Tire Rotation Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km)
Transmission Fluid Change Interval:
Manual: Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on usage. Automatic: Every 30,000 - 50,000 miles (48,000 - 80,000 km).
Coolant Change Interval:
Every 30,000 miles (48,000 km) or 2 years
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for standard plugs, potentially longer for platinum/iridium.
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 10W-30 (check owner's manual for specific temp range recommendations).
Engine Coolant Specification:
Chrysler Formula 05103530AA (Green) or equivalent HOAT coolant.
Fluid Capacities
Engine Oil Capacity:
5.0 US quarts (4.7 L) with filter for 4.0L I6
Coolant Capacity:
Approx. 11.0 US quarts (10.4 L) for 4.0L I6
Fuel Tank Capacity:
15.0 US gallons (56.8 L)
Known Issues
Common Issues 40L:
Cracked cylinder heads (early 4.0L engines), oil filter housing leaks, exhaust manifold cracks, tappet noise.
Common Issues Suspension Steering:
Worn steering box, track bar bushings, ball joints, control arm bushings.
Common Issues Electrical:
Faulty ASD (Auto Shutdown) relay, instrument cluster issues, power window/lock failures.
Common Issues Transfer Case:
Chain stretch in NP231, worn shift linkage.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Direct descendant of the WWII Willys Jeep, known for ruggedness and off-road prowess.
Model Evolution
Tj Generation Launch:
Introduced for the 1997 model year, replacing the YJ generation. The TJ marked a significant return to the CJ-style round headlights and coil-spring suspension.
Tj Key Changes 1999:
1999 saw the introduction of the optional NV3550 5-speed manual transmission for 4.0L engines, replacing the AX-5 in many configurations for improved durability and lower gearing.
Production
Production Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Magazine Awards:
Consistently recognized by off-road publications for its capability and iconic status.
Ratings
Consumer Reports:
Often cited for mechanical reliability of the 4.0L engine, but with typical American vehicle ratings for the era regarding build quality and electronics.
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