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Jeep Cherokee XJ 1999 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: XJ Year: 1999 Codes Chassis Code: XJ Platform: Jeep Cherokee (XJ) 👋 Introduction Market Position Description: The Jeep Cherokee XJ (1999 model year) represented a stalwart in the compact SUV segment, known for its robust build, off-road capability, and utilitarian design. It competed with vehicles like the Toyota RAV4, Honda CR-V, and Ford Explorer. Competitive Analysis Key Selling Points: Unibody construction offering a balance of rigidity and weight, legendary Jeep 4x4 systems, strong aftermarket support for customization and off-road modifications. Key Features Vehicle Features: Available in 2-door and 4-door configurations, iconic Jeep styling, Command-Trac and Selec-Trac 4WD systems, comfortable ride for its class, proven drivetrain components. Manual Purpose Target Audience: Primarily professional technicians, but also highly valuable for advanced DIY enthusiasts and restoration specialists. 📋 Manual Details Coverage Areas Vehicle Coverage: All 1999 Jeep Cherokee XJ models (North American specifications) Engine Coverage: 4.0L (242ci) Inline 6-Cylinder (High Output) and 2.5L (150ci) Inline 4-Cylinder Transmission Coverage: 42RE (4-speed Automatic), AX-15 (5-speed Manual), NV3550 (5-speed Manual) Drivetrain Coverage: 2WD (RWD), 4WD (Part-Time Command-Trac, Selec-Trac) Page Count Estimated Page Count: 1000+ Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection (MPI), ignition, cooling, lubrication, exhaust, engine performance diagnostics, emissions control. Transmission And Drivetrain: Automatic and manual transmission repair, transfer case operation and repair, driveline components, axles, differentials, CV joints. Suspension And Steering: Front and rear suspension (leaf spring and coil spring variants), steering system (power steering, linkages, steering column), wheel alignment. Brakes: Front and rear brake systems (disc and drum configurations), ABS (if equipped), hydraulic system, parking brake. Electrical: Battery, charging system, starting system, lighting, gauges, instrument cluster, power windows/locks, body control modules, fuses, relays, wiring diagrams. Body And Chassis: Body construction, exterior trim, interior components, seats, HVAC system, doors, windows, body panel repair, chassis diagnostics. Procedures Included Maintenance Procedures: Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication points. Repair Procedures: Component removal and installation, detailed rebuild procedures for major components (engine, transmission), diagnostic and repair of common faults. Troubleshooting: System-specific diagnostic flowcharts, symptom-based troubleshooting guides, identification of common failure modes. Technical Data: Torque specifications, clearances, timing settings, diagnostic trouble codes (DTCs) and their meanings, wiring diagrams, exploded views. Technical Depth Depth: Comprehensive, covering diagnostics, repair, overhaul, and troubleshooting for all major vehicle systems. Suitable for professional technicians and experienced DIYers. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with clear text and legible diagrams. Printable: Yes, printable for convenient workshop use. Print Quality Print Quality: N/A (Digital Download) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 4.0L (3960cc) Engine 1 Type: Inline 6-Cylinder, Overhead Valve (OHV) Engine 1 Bore X Stroke: 3.875 in x 3.562 in (98.4 mm x 90.5 mm) Engine 1 Compression Ratio: 8.8:1 Engine 1 Horsepower: 190 hp @ 4600 rpm Engine 1 Torque: 225 lb-ft @ 3000 rpm Secondary Engine Engine 2 Displacement: 2.5L (2507cc) Engine 2 Type: Inline 4-Cylinder, Overhead Valve (OHV) Engine 2 Horsepower: 125 hp @ 4600 rpm Engine 2 Torque: 150 lb-ft @ 2400 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Ignition Ignition System: Distributorless Ignition System (DIS) with Distributor Ignition (DI) system for 2.5L engine. Cooling Cooling System Type: Pressurized, liquid-cooled Lubrication Oil Capacity 4.0L: 5 US quarts (4.7 L) with filter change Oil Capacity 2.5L: 5 US quarts (4.7 L) with filter change 🔧 Transmission Standard Standard Transmission: Typically 4-speed automatic (42RE) for most trims; 5-speed manual (AX-15 or NV3550) was an option. Optional Optional Transmission: AX-15 (5-speed Manual) or NV3550 (5-speed Manual) depending on engine and trim. Features Automatic Transmission Features: 42RE with Overdrive (4th gear), electronic controls. Manual Transmission Features: Durable, direct-shift designs suitable for off-road use. Transfer Case Transfer Case Options: Command-Trac (NV231) - Part-time, 2WD/4WD High/Neutral/4WD Low; Selec-Trac (NV242) - Full-time 4WD/Part-time 4WD High/Neutral/4WD Low. Fluid Specifications Automatic Transmission Fluid: ATF+4 (Chrysler Material Standard MS-9602) or equivalent Manual Transmission Fluid: API GL-5, SAE 75W-90 gear oil (AX-15); Manual Transmission Lubricant (Chrysler MS-9224) or equivalent for NV3550. 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 166.4 inches (4226 mm) Width: 70.1 inches (1781 mm) Height: 64.4 inches (1636 mm) Ground Clearance: Approx. 8.5 inches (216 mm) depending on configuration. Weights Curb Weight Approx: 3,500 - 3,900 lbs (1588 - 1769 kg) Gross Vehicle Weight Rating Gvwr: Approx. 4,750 - 5,100 lbs (2154 - 2313 kg) Cargo Cargo Volume Behind Rear Seat: Approx. 32.2 cu ft (0.91 m³) Cargo Volume With Rear Seat Folded: Approx. 69.0 cu ft (1.95 m³) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: Not explicitly rated for 1999 model...
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Jeep Cherokee XJ 1999 Workshop Service Manual Repair
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Model Code:
XJ
Year:
1999
Codes
Chassis Code:
XJ
Platform:
Jeep Cherokee (XJ)
👋 Introduction
Market Position
Description:
The Jeep Cherokee XJ (1999 model year) represented a stalwart in the compact SUV segment, known for its robust build, off-road capability, and utilitarian design. It competed with vehicles like the Toyota RAV4, Honda CR-V, and Ford Explorer.
Competitive Analysis
Key Selling Points:
Unibody construction offering a balance of rigidity and weight, legendary Jeep 4x4 systems, strong aftermarket support for customization and off-road modifications.
Key Features
Vehicle Features:
Available in 2-door and 4-door configurations, iconic Jeep styling, Command-Trac and Selec-Trac 4WD systems, comfortable ride for its class, proven drivetrain components.
Manual Purpose
Target Audience:
Primarily professional technicians, but also highly valuable for advanced DIY enthusiasts and restoration specialists.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
All 1999 Jeep Cherokee XJ models (North American specifications)
Engine Coverage:
4.0L (242ci) Inline 6-Cylinder (High Output) and 2.5L (150ci) Inline 4-Cylinder
Transmission Coverage:
42RE (4-speed Automatic), AX-15 (5-speed Manual), NV3550 (5-speed Manual)
Drivetrain Coverage:
2WD (RWD), 4WD (Part-Time Command-Trac, Selec-Trac)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection (MPI), ignition, cooling, lubrication, exhaust, engine performance diagnostics, emissions control.
Transmission And Drivetrain:
Automatic and manual transmission repair, transfer case operation and repair, driveline components, axles, differentials, CV joints.
Suspension And Steering:
Front and rear suspension (leaf spring and coil spring variants), steering system (power steering, linkages, steering column), wheel alignment.
Brakes:
Front and rear brake systems (disc and drum configurations), ABS (if equipped), hydraulic system, parking brake.
Electrical:
Battery, charging system, starting system, lighting, gauges, instrument cluster, power windows/locks, body control modules, fuses, relays, wiring diagrams.
Body And Chassis:
Body construction, exterior trim, interior components, seats, HVAC system, doors, windows, body panel repair, chassis diagnostics.
Procedures Included
Maintenance Procedures:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication points.
Repair Procedures:
Component removal and installation, detailed rebuild procedures for major components (engine, transmission), diagnostic and repair of common faults.
Troubleshooting:
System-specific diagnostic flowcharts, symptom-based troubleshooting guides, identification of common failure modes.
Technical Data:
Torque specifications, clearances, timing settings, diagnostic trouble codes (DTCs) and their meanings, wiring diagrams, exploded views.
Technical Depth
Depth:
Comprehensive, covering diagnostics, repair, overhaul, and troubleshooting for all major vehicle systems. Suitable for professional technicians and experienced DIYers.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable PDF with clear text and legible diagrams.
Printable:
Yes, printable for convenient workshop use.
Print Quality
Print Quality:
N/A (Digital Download)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
4.0L (3960cc)
Engine 1 Type:
Inline 6-Cylinder, Overhead Valve (OHV)
Engine 1 Bore X Stroke:
3.875 in x 3.562 in (98.4 mm x 90.5 mm)
Engine 1 Compression Ratio:
8.8:1
Engine 1 Horsepower:
190 hp @ 4600 rpm
Engine 1 Torque:
225 lb-ft @ 3000 rpm
Secondary Engine
Engine 2 Displacement:
2.5L (2507cc)
Engine 2 Type:
Inline 4-Cylinder, Overhead Valve (OHV)
Engine 2 Horsepower:
125 hp @ 4600 rpm
Engine 2 Torque:
150 lb-ft @ 2400 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
Distributorless Ignition System (DIS) with Distributor Ignition (DI) system for 2.5L engine.
Cooling
Cooling System Type:
Pressurized, liquid-cooled
Lubrication
Oil Capacity 4.0L:
5 US quarts (4.7 L) with filter change
Oil Capacity 2.5L:
5 US quarts (4.7 L) with filter change
🔧 Transmission
Standard
Standard Transmission:
Typically 4-speed automatic (42RE) for most trims; 5-speed manual (AX-15 or NV3550) was an option.
Optional
Optional Transmission:
AX-15 (5-speed Manual) or NV3550 (5-speed Manual) depending on engine and trim.
Features
Automatic Transmission Features:
42RE with Overdrive (4th gear), electronic controls.
Manual Transmission Features:
Durable, direct-shift designs suitable for off-road use.
Transfer Case
Transfer Case Options:
Command-Trac (NV231) - Part-time, 2WD/4WD High/Neutral/4WD Low; Selec-Trac (NV242) - Full-time 4WD/Part-time 4WD High/Neutral/4WD Low.
Fluid Specifications
Automatic Transmission Fluid:
ATF+4 (Chrysler Material Standard MS-9602) or equivalent
Manual Transmission Fluid:
API GL-5, SAE 75W-90 gear oil (AX-15); Manual Transmission Lubricant (Chrysler MS-9224) or equivalent for NV3550.
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
166.4 inches (4226 mm)
Width:
70.1 inches (1781 mm)
Height:
64.4 inches (1636 mm)
Ground Clearance:
Approx. 8.5 inches (216 mm) depending on configuration.
Weights
Curb Weight Approx:
3,500 - 3,900 lbs (1588 - 1769 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 4,750 - 5,100 lbs (2154 - 2313 kg)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 32.2 cu ft (0.91 m³)
Cargo Volume With Rear Seat Folded:
Approx. 69.0 cu ft (1.95 m³)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Not explicitly rated for 1999 model year in standardized formats available today, but generally considered robust for its era.
NHTSA Frontal Impact Passenger:
Not explicitly rated for 1999 model year.
Active Features
Braking System:
Standard front disc brakes, rear drum brakes. Optional Anti-lock Braking System (ABS) available on rear wheels.
Traction Control:
Limited slip differentials (LSD) were optional on some trims. No electronic traction control systems as found in modern vehicles.
Passive Features
Airbags:
Driver and passenger front airbags.
Seat Belts:
Three-point inertia-reel seat belts in the front and rear (outboard positions).
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system not standard or widely implemented in this model year.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player. Optional CD player or premium sound system. Aftermarket head unit support is extensive.
Navigation:
No factory navigation system available for this model year.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on rear wheels only.
Cruise Control:
Standard on most trims.
Other Features:
Power windows, power door locks, remote keyless entry (optional on higher trims).
Connectivity
Auxiliary Input:
No factory auxiliary audio input (3.5mm jack) or USB ports.
Bluetooth:
No factory Bluetooth connectivity.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 3-6 months, depending on driving conditions. Refer to manual for severe service recommendations.
Engine Coolant:
Every 30,000 miles (48,000 km) or 2 years for initial change, then every 15,000 miles (24,000 km) or 1 year thereafter. (Chrysler HOAT coolant recommended).
Automatic Transmission Fluid:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-3 years, depending on driving conditions. Inspect fluid condition regularly.
Spark Plugs:
4.0L: Approximately 60,000 - 100,000 miles (96,000 - 160,000 km) depending on plug type. 2.5L: Approximately 30,000 - 60,000 miles (48,000 - 96,000 km).
Air Filter:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving environment.
Fluid Specifications
Engine Oil:
SAE 10W-30 or 10W-40 for 4.0L; SAE 5W-30 or 10W-30 for 2.5L. Check owner's manual for specific temperature ranges and API service classification (e.g., API SN or equivalent).
Coolant:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically orange or red. Mix 50/50 with distilled water.
Brake Fluid:
DOT 3 (or DOT 4 if specified in manual) brake fluid.
Power Steering Fluid:
Chrysler Power Steering Fluid (or equivalent like ATF+4 if specified).
Known Issues
Common Faults 4.0L:
Head gasket failures (earlier models prone, less common in '99), cracked cylinder heads (less common in '99), radiator leaks, cooling fan clutch issues, exhaust manifold cracks, TPS (Throttle Position Sensor) failures.
Common Faults 2.5L:
Engine oil leaks, valve cover gasket leaks, potential for head gasket issues similar to 4.0L if overheated.
Common Faults Transmission:
Solenoid pack failures in 42RE automatic, input shaft wear in AX-15 manual, clutch wear in manual transmissions.
Common Faults Electrical:
Window motor failures, interior light issues, instrument cluster problems (intermittent gauge operation), O2 sensor failures.
Common Faults Chassis Suspension:
Leaf spring sag (rear), worn ball joints and tie rod ends, steering box wear, U-joint failure in driveshafts, rust (especially in northern climates).
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a storied history dating back to World War II, renowned for its off-road prowess and ruggedness. The Cherokee nameplate itself has been central to Jeep's identity.
Model Evolution
Xj Generation Timeline:
The XJ Cherokee was introduced in 1984, pioneering the compact SUV segment with its unibody construction. The 1999 model year falls within the second generation of the XJ, which saw significant updates including revised interiors, improved aerodynamics, and engine advancements.
Production
Xj Production Years:
1984-2001 (North America)
Manufacturing Locations:
Primarily Toledo, Ohio, USA.
Model Year Changes 1999
Key Updates:
Minor exterior styling tweaks (revised front fascia, grille, and headlights), updated interior ergonomics and materials, improved NVH (Noise, Vibration, Harshness) levels, new Selec-Trac NV242 transfer case option for greater refinement.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the 1999 model year are not prominently documented, the Cherokee XJ generation consistently received praise for its off-road capability and value throughout its production run, often being recognized by automotive publications for its utility and durability.
Ratings
Consumer Reports:
Consumer Reports typically rated the Cherokee XJ for its off-road capability but often flagged reliability concerns in certain areas, especially regarding the transmission and powertrain in earlier years. Later models like the 1999 generally showed improved reliability scores, though still not always class-leading.
Certifications
Emissions Certification:
Compliant with 1999 US Federal Emissions Standards. Manual will detail specific emissions control systems and diagnostic procedures.
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