Jeep Cherokee Cherokee XJ, including SE, Sport, Classic, and Limited 2.5L and 4.0L Engines 1999 Service & Repair Manual (P/N 81-370-9146)

This 1,948-page PDF brings together the factory service content for the 1999 Jeep Cherokee XJ, including the SE, Sport, Classic, and Limited series identified in the vehicle information. Its procedure depth and reliance on scan tools, presses, precision gauges, and Chrysler service tools make it best suited to professional technicians and experienced XJ owners with established repair skills and shop equipment.

• Coverage and document identity: 1999 Cherokee XJ, 2-door and 4-door bodies, 2WD and 4WD, LHD and RHD, with Publication No. 81-370-9146.
• Covers the 2.5L and 4.0L MPI gasoline engines plus the manual's 2.5L VM diesel supplemental sections, including engine removal, cylinder-head and valve-train work, timing service, lubrication diagnosis, cooling-system testing, and fuel-system repair.
• Walks through AX5 and AX15 manual transmissions and 30RH and AW-4 automatics, with removal, internal disassembly and inspection, reassembly, hydraulic testing, torque-converter service, and cable or band adjustment where applicable.
• Details NV231 and NV242 transfer cases and the 181 FBI, 194 RBI, and Chrysler 8 1/4 axles, including shaft and bearing replacement, differential overhaul, pinion-depth setup, bearing preload, ring-gear backlash, tooth-contact checks, and Trac-Lok service.
• Includes wheel alignment, front and rear suspension, steering, base and ABS brakes, clutch, body, HVAC, restraints, and accessory-system repair, backed by torque tables, fluid and capacity data, wear limits, clearances, and adjustment specifications.
• Provides the full Group 8W wiring section, with power and ground distribution, fuel/ignition and transmission-control circuits, connector pin-outs and locations, splice maps, and system-specific electrical fault tracing.

Engine, Transmission, and Axle Repair Depth

The gasoline engine chapters cover compression and oil-pressure diagnosis, valve timing, cylinder-head and camshaft removal, bearing fitting, rear main seals, oil pumps, pistons and connecting rods, and short-block service. The diesel supplement adds mechanical and performance diagnosis, cylinder-liner work, the internal vacuum pump, turbocharger and manifolds, diesel injection equipment, glow-plug controls, and LHD/RHD engine-mount differences.

Transmission coverage extends through internal repair. The 30RH section includes road, stall, air, and hydraulic-pressure testing plus valve-body, clutch, servo, governor, planetary, and band work. AW-4 coverage adds TCM inputs, solenoid and speed-sensor tests, time-lag analysis, clutch and brake packs, valve-body overhaul, and planetary assemblies. The manual gearboxes receive geartrain, synchronizer, shaft, bearing, seal, and shift-mechanism procedures; both transfer cases have removal, teardown, inspection, reassembly, and linkage-adjustment coverage.

Diagnostics, Wiring, and Visual References

The manual supplies diagnostic charts, DTC information, component tests, operating descriptions, and connector-level electrical data. Named visual references include the Oil Lubrication System - 2.5L Engine, Oil Lubrication System - 4.0L Engine, 30RH Hydraulic Schematics, Fuel/Ignition System wiring, Transmission Control System wiring, and the Connector Pin-Outs/Connector Locations sections. ABS, airbag, HVAC, Sentry Key, lighting, trailer-tow, power-distribution, splice, and ground circuits are also mapped.

The complete guided scan-tool routines are contained in separate Diagnostic Procedures or Powertrain Diagnostic Procedures manuals and are not included in this PDF. The service manual directs several PCM, ABS, airbag, Sentry Key, and diesel control tests to those companion publications while retaining the related wiring, component checks, DTC lists, and mechanical repair procedures.

Factory Tools, Specifications, and Shop Cautions

Factory tool plates identify equipment such as Pinion Depth Tool Set 6774, Spreader W-129-B, Trac-Lok Tool Set 6960, and Timing Case Cover Alignment and Seal Installation Tool 6139, plus many assembly-specific pullers, installers, fixtures, and gauges. The diagnostic sections also call out the DRB III scan tool where electronic testing requires it.

The axle chapters warn that pinion preload must not be reduced by backing off the nut; an over-crushed collapsible spacer has to be replaced or the spacer and bearings can be damaged. The 30RH procedure calls for the transmission and torque converter to be removed together because leaving the converter on the driveplate can damage the driveplate, pump bushing, or oil seal.

For suspension, axle, or transmission work, follow the manual's hoisting guidance: support the vehicle on rated stands at the front and rear ends of the frame rails, and never position a floor jack under an axle tube, body sill, steering-linkage component, or driveshaft.