1999 Jeep Wrangler (Tj) Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation Code: TJ Year: 1999 👋 Introduction Market Position Vehicle Class: Compact SUV / Off-road Vehicle Segment Appeal: Known for its iconic off-road capability, ruggedness, and open-air driving experience. Competitive Analysis Direct Competitors 1999: Ford Bronco (discontinued), Toyota 4Runner, Nissan Xterra, Chevrolet Tracker. Key Features Iconic Design: Classic Jeep styling with removable doors and tops. Off Road Capability: Solid axles, robust suspension, available 4x4 systems (Command-Trac). Durability: Built with durable components for demanding use. 📋 Manual Details Coverage Areas Engine Coverage: Yes Transmission Coverage: Yes Chassis Coverage: Yes Electrical Coverage: Yes Body Coverage: Yes Suspension Coverage: Yes Brakes Coverage: Yes Steering Coverage: Yes HVAC Coverage: Yes Diagnostic Procedures: Yes Troubleshooting Guides: Yes Page Count Estimated Pages: Over 1000 Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder heads, pistons, crankshaft, camshaft, timing, lubrication system, cooling system, fuel system (mechanical components), exhaust system (mechanical components). Engine Performance: Engine tuning, ignition system, fuel injection system (electronic), emissions control systems (EVAP, EGR). Transmission Manual: Clutch system, manual gearbox assembly, shift linkage, driveline (U-joints, driveshafts). Transmission Automatic: Automatic transmission assembly (if applicable to specific powertrain), torque converter, transmission control module (TCM), fluid and cooling. Transfer Case: NV231 Command-Trac transfer case service, maintenance, and diagnostics. Suspension Front: Solid front axle, Quadra-Coil suspension, control arms, sway bar, shocks, springs. Suspension Rear: Solid rear axle, Quadra-Coil suspension, control arms, Panhard rod, track bar, shocks, springs. Brakes Front: Disc brake system, calipers, rotors, brake pads, brake lines, ABS (if equipped). Brakes Rear: Disc brake system (typically), calipers, rotors, brake pads, brake lines, ABS (if equipped). Steering: Steering gearbox, steering column, power steering pump, hoses, tie rods, drag link. Electrical System: Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams for all circuits. Lighting System: Headlights, taillights, turn signals, interior lighting, wiring and bulb specifications. HVAC System: Air conditioning system, heater core, blower motor, controls, refrigerant. Body Panels: Door mechanisms, hood, tailgate, fenders, bumpers, body trim, convertible top (soft top and hard top removal/installation). Interior Components: Seating, dashboard, instrument cluster, interior trim panels, sound insulation. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), fluid checks and top-offs, tire rotation, spark plug replacement, battery maintenance. Major Repairs: Engine overhaul, transmission rebuild, differential service, axle repair, brake system overhaul, steering system rebuild. Diagnostics: Step-by-step diagnostic flowcharts for common issues, symptom-based troubleshooting, diagnostic trouble codes (DTCs) and their meanings. Troubleshooting: Guides for diagnosing and fixing problems related to starting, running, electrical systems, cooling, brakes, etc. Assembly Disassembly: Detailed instructions for removing and reinstalling major components and sub-assemblies. Torque Specifications: Essential torque values for all critical fasteners. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Technical Service Bulletins Reference: Likely references or includes information often found in TSBs regarding common issues and fixes. Technical Depth Depth: Comprehensive and detailed, suitable for both DIY enthusiasts and professional mechanics. Detail Level: Provides detailed explanations, diagrams, and step-by-step instructions for repairs and maintenance. 📊 Manual Specifications File Format Format: PDF Searchable Text: Yes Printable: Yes Print Quality Image Resolution: High-resolution for clear diagrams and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 3RZ-FE (Commonly referenced, but TJ Wrangler used Jeep/Chrysler engines) Engine Type: Inline 4-cylinder (Standard for 1999 TJ) Displacement Liters: 2.5 Displacement Cid: 150 Horsepower Hp: 117 Torque Lb Ft: 135 Fuel Delivery: Multi-port Fuel Injection (MPI) Ignition System: Distributorless Ignition System (DIS) with coil-on-plug or coil pack. Cooling System: Pressurized liquid cooling system. Emissions Controls: Catalytic converter, EGR, EVAP system. Optional Engine Engine Type: Inline 6-cylinder (Optional for 1999 TJ) Engine Code: 4.0L (often referred to as the 'PowerTech' inline-6) Displacement Liters: 4.0 Displacement Cid: 242 Horsepower Hp: 181 Torque Lb Ft: 222 Fuel Delivery: Multi-port Fuel Injection (MPI) Ignition System: Distributorless Ignition System (DIS) with coil pack. 🔧 Transmission Standard Transmission Type: 5-Speed Manual (NV3550 for 2.5L, NSG370 for 4.0L later TJ, but likely AX-15 for early 4.0L TJ or related variant) Optional Transmission Type: 4-Speed Automatic (42RLE for later TJ, but likely AW4 for early TJ) Features Clutch Type: Hydraulically actuated single dry plate. Gear Ratios Manual: Specific ratios for each transmission variant (e.g., AX-15, NV3550) will be detailed in the manual. Gear Ratios Automatic: Specific ratios for each transmission variant (e.g., AW4) will be detailed in the manual. Transfer Case Model: NV231 Command-Trac (Part-time 2-speed with 4WD Low) Transfer Case Gear Ratios: Low range ratio: 2.72:1 Fluid Specifications Manual Transmission Fluid: API GL-3 or GL-4, SAE 75W-90 (Specific brands/types detailed in manual). Automatic Transmission Fluid: ATF+4 (or equivalent as specified by manufacturer for the specific transmission). Transfer Case Fluid: Mopar NV231 Transfer Case Fluid or equivalent (e.g.,...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation Code:

Year:

👋 Introduction

Market Position

Vehicle Class:

Compact SUV / Off-road Vehicle

Segment Appeal:

Known for its iconic off-road capability, ruggedness, and open-air driving experience.

Competitive Analysis

Direct Competitors 1999:

Ford Bronco (discontinued), Toyota 4Runner, Nissan Xterra, Chevrolet Tracker.

Key Features

Iconic Design:

Classic Jeep styling with removable doors and tops.

Off Road Capability:

Solid axles, robust suspension, available 4x4 systems (Command-Trac).

Durability:

Built with durable components for demanding use.

📋 Manual Details

Coverage Areas

Engine Coverage:

Transmission Coverage:

Chassis Coverage:

Electrical Coverage:

Body Coverage:

Suspension Coverage:

Brakes Coverage:

Steering Coverage:

HVAC Coverage:

Diagnostic Procedures:

Troubleshooting Guides:

Page Count

Estimated Pages:

Over 1000

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder heads, pistons, crankshaft, camshaft, timing, lubrication system, cooling system, fuel system (mechanical components), exhaust system (mechanical components).

Engine Performance:

Engine tuning, ignition system, fuel injection system (electronic), emissions control systems (EVAP, EGR).

Transmission Manual:

Clutch system, manual gearbox assembly, shift linkage, driveline (U-joints, driveshafts).

Transmission Automatic:

Automatic transmission assembly (if applicable to specific powertrain), torque converter, transmission control module (TCM), fluid and cooling.

Transfer Case:

NV231 Command-Trac transfer case service, maintenance, and diagnostics.

Suspension Front:

Solid front axle, Quadra-Coil suspension, control arms, sway bar, shocks, springs.

Suspension Rear:

Solid rear axle, Quadra-Coil suspension, control arms, Panhard rod, track bar, shocks, springs.

Brakes Front:

Disc brake system, calipers, rotors, brake pads, brake lines, ABS (if equipped).

Brakes Rear:

Disc brake system (typically), calipers, rotors, brake pads, brake lines, ABS (if equipped).

Steering:

Steering gearbox, steering column, power steering pump, hoses, tie rods, drag link.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams for all circuits.

Lighting System:

Headlights, taillights, turn signals, interior lighting, wiring and bulb specifications.

HVAC System:

Air conditioning system, heater core, blower motor, controls, refrigerant.

Body Panels:

Door mechanisms, hood, tailgate, fenders, bumpers, body trim, convertible top (soft top and hard top removal/installation).

Interior Components:

Seating, dashboard, instrument cluster, interior trim panels, sound insulation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), fluid checks and top-offs, tire rotation, spark plug replacement, battery maintenance.

Major Repairs:

Engine overhaul, transmission rebuild, differential service, axle repair, brake system overhaul, steering system rebuild.

Diagnostics:

Step-by-step diagnostic flowcharts for common issues, symptom-based troubleshooting, diagnostic trouble codes (DTCs) and their meanings.

Troubleshooting:

Guides for diagnosing and fixing problems related to starting, running, electrical systems, cooling, brakes, etc.

Assembly Disassembly:

Detailed instructions for removing and reinstalling major components and sub-assemblies.

Torque Specifications:

Essential torque values for all critical fasteners.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Technical Service Bulletins Reference:

Likely references or includes information often found in TSBs regarding common issues and fixes.

Technical Depth

Depth:

Comprehensive and detailed, suitable for both DIY enthusiasts and professional mechanics.

Detail Level:

Provides detailed explanations, diagrams, and step-by-step instructions for repairs and maintenance.

📊 Manual Specifications

File Format

Format:

Searchable Text:

Printable:

Print Quality

Image Resolution:

High-resolution for clear diagrams and illustrations.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

3RZ-FE (Commonly referenced, but TJ Wrangler used Jeep/Chrysler engines)

Engine Type:

Inline 4-cylinder (Standard for 1999 TJ)

Displacement Liters:

Displacement Cid:

Horsepower Hp:

Torque Lb Ft:

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug or coil pack.

Cooling System:

Pressurized liquid cooling system.

Emissions Controls:

Catalytic converter, EGR, EVAP system.

Optional Engine

Engine Type:

Inline 6-cylinder (Optional for 1999 TJ)

Engine Code:

4.0L (often referred to as the 'PowerTech' inline-6)

Displacement Liters:

Displacement Cid:

Horsepower Hp:

Torque Lb Ft:

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with coil pack.

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual (NV3550 for 2.5L, NSG370 for 4.0L later TJ, but likely AX-15 for early 4.0L TJ or related variant)

Optional

Transmission Type:

4-Speed Automatic (42RLE for later TJ, but likely AW4 for early TJ)

Features

Clutch Type:

Hydraulically actuated single dry plate.

Gear Ratios Manual:

Specific ratios for each transmission variant (e.g., AX-15, NV3550) will be detailed in the manual.

Gear Ratios Automatic:

Specific ratios for each transmission variant (e.g., AW4) will be detailed in the manual.

Transfer Case Model:

NV231 Command-Trac (Part-time 2-speed with 4WD Low)

Transfer Case Gear Ratios:

Low range ratio: 2.72:1

Fluid Specifications

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 (Specific brands/types detailed in manual).

Automatic Transmission Fluid:

ATF+4 (or equivalent as specified by manufacturer for the specific transmission).

Transfer Case Fluid:

Mopar NV231 Transfer Case Fluid or equivalent (e.g., Dexron III MERCON).

📐 Dimensions

Exterior

Wheelbase Inches:

Overall Length Inches:

151.4

Overall Width Inches:

Overall Height Inches:

71.5 (soft top)

Ground Clearance Inches:

Approx. 8.8

Approach Angle Degrees:

Approx. 41

Departure Angle Degrees:

Approx. 36

Breakover Angle Degrees:

Approx. 26

Weights

Curb Weight Lbs:

Approx. 3,300 - 3,600 (depending on configuration)

Gross Vehicle Weight Rating Gvwr Lbs:

Approx. 4,600

Towing Capacity Lbs:

2,000

Payload Capacity Lbs:

Approx. 1,000 - 1,300

Wheels Tires

Standard Wheel Size:

15x8 inch

Standard Tire Size:

30x9.50R15

Bolt Pattern:

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

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating:

Not directly rated by NHTSA in a way comparable to modern vehicles, focus was on ruggedness and off-road safety.

IIHS Ratings:

Generally not rated by IIHS due to its niche off-road design and testing protocols of the era.

Active Features

Available (typically rear-wheel anti-lock brakes on 4x4 models, or full ABS on some trims/options)

Traction Control:

Not typically available on 1999 models.

Passive Features

Airbags:

Driver and passenger airbags

Seatbelts:

Three-point front seatbelts, lap belts in rear (depending on configuration).

Rollover Protection:

Integrated sport bar behind front seats, reinforced windshield frame.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD or Cassette player with basic speaker system. Aftermarket options common.

Navigation:

Not available from factory.

Connectivity:

No Bluetooth or USB connectivity from factory.

Driver Assistance

Cruise Control:

Available on higher trim levels or as an option.

Parking Sensors:

Not available.

Backup Camera:

Not available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for specific engine/oil type).

Air Filter Replacement:

Every 15,000-30,000 miles or annually.

Spark Plug Replacement:

Every 30,000-60,000 miles depending on plug type (standard vs. platinum/iridium).

Coolant Flush Interval:

Every 30,000 miles or 2 years.

Transmission Fluid Change Manual:

Every 60,000 miles or 4 years.

Transmission Fluid Change Automatic:

Every 30,000-50,000 miles or 3 years.

Brake Fluid Change:

Every 24,000 miles or 2 years.

Fluid Specifications

Engine Oil Type:

SAE 10W-30 or 10W-40 (refer to owner's manual for specific engine and temperature range).

Engine Oil Capacity Quarts 2.5L:

4.5 (with filter)

Engine Oil Capacity Quarts 4.0L:

5.0 (with filter)

Coolant Type:

Chrysler Long Life (Red) or equivalent HOAT coolant.

Coolant Capacity Quarts:

Approx. 11.3

Power Steering Fluid:

ATF+3 or ATF+4 (refer to manual for specific recommendation).

Known Issues

Common Wear Item 1:

Leaf spring bushings (though TJ has coils, control arm bushings are common wear items).

Common Wear Item 2:

U-joints and CV joints on driveshafts (due to off-road use and angles).

Common Issue 1:

Radiator leaks (plastic tanks can degrade).

Common Issue 2:

Oil filter adapter housing leaks.

Common Issue 3:

Tire wear due to camber alignment issues (especially with lifted vehicles).

Common Issue 4:

Interior water leaks around windshield frame and door seals.

Common Issue 5:

Clutch wear (especially with heavy off-road use).

📚 Vehicle History

Brand Heritage

Brand Origin:

Willys-Overland CJ series, evolving into Jeep CJ, and then Wrangler.

Jeep Legacy:

Deep roots in military vehicles, synonymous with off-road capability and freedom.

Model Evolution

Tj Introduction:

Introduced for the 1997 model year, replacing the YJ generation.

Tj Key Changes From Yj:

Return to coil springs (Quadra-Coil suspension) for improved ride quality and articulation, elimination of leaf springs on both axles.

Tj Powertrain Options:

Initially 2.5L I4 and 4.0L I6. Transmission options included manual and automatic.

Tj Design Philosophy:

Modernized yet retained classic Jeep styling and off-road prowess.

Production

Production Years Tj:

1997-2006

Manufacturing Plant:

Toledo, Ohio, USA

Ownership During Era:

Chrysler Corporation (later DaimlerChrysler).

🏆 Awards & Recognition

Recognitions

4X4 Of The Year:

Frequently recognized by off-road publications and enthusiasts for its class-leading capability.

Customization Potential:

Widely regarded as one of the most customizable vehicles for off-road modifications.