1999 Jeep Cherokee Service & Repair Manual

GROUP TAB LOCATOR IN Introduction INa Introduction 0 Lubrication and Maintenance 0a Lubrication and Maintenance 2 Suspension 3 Differential and Driveline 5 Brakes 6 Clutch 6a Clutch 7 Cooling System 7a Cooling System 8A Battery 8B Starting System 8Ba Starting Systems 8C Charging System 8Ca Charging System 8D Ignition System 8E Instrument Panel Systems 8Ea Instrument Panel Systems 8F Audio Systems 8G Horn Systems 8H Vehicle Speed Control System 8Ha Vehicle Speed Control System 8J Turn Signal and Hazard Warning Systems 8K Wiper and Washer Systems 8L Lamps 8La Lamps 8M Passive Restraint Systems 8N Electrically Heated Systems 8O Power Distribution Systems 8P Power Lock Systems 8Q Vehicle Theft/Security Systems 8Qa Vehicle Theft/Security Systems 8R Power Seats Systems 8S Power Window Systems 8T Power Mirror Systems 8U Chime/Buzzer Warning Systems 8V Overhead Console Systems 8W Wiring Diagrams 9 Engine 9a Engine 11 Exhaust System and Intake Manifold 11a Exhaust System and Intake Manifold 13 Frame and Bumpers 13a Frame and Bumpers 14 Fuel System 14a Fuel System–2.5L Diesel Engine 19 Steering 19a Steering 21 Transmission and Transfer Case 21a Transmission and Transfer Case 22 Tires and Wheels 23 Body 24 Heating and Air Conditioning 24a Heating and Air Conditioning 25 Emission Control Systems 25a Emission Control System

INTRODUCTION CONTENTS page page GENERAL INFORMATION BODY CODE PLATE ...................... 2 FASTENER IDENTIFICATION ................ 4 FASTENER USAGE ....................... 7 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS .................... 3 METRIC SYSTEM ........................ 7 THREADED HOLE REPAIR ................. 7 TORQUE REFERENCES .................... 9 VEHICLE IDENTIFICATION NUMBER ......... 1 VEHICLE SAFETY CERTIFICATION LABEL ..... 2 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left A-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle. The Vehicle Identification Number is also imprinted on the: • Body Code Plate. • Vehicle Safety Certification Label. • Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden- tification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta- tion. The formula to use the check digit is not released to the general public. VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = United States 2 Make J = Jeep 3 Vehicle Type 4 = MPV 4 Gross Vehicle Weight Rating F = 4001-5000 lbs. 5 Vehicle Line F= Cherokee 4X4 (LHD) N = Cherokee 4X4 (RHD) B = Cherokee 4X2 (RHD) T = Cherokee 4X2 (LHD) 6 Series 2 = SE 6 = Sport/Classic 7 = Limited 7 Body Style 7 = 2dr Sport Utility 8 = 4dr Sport Utility 8 Engine P = 2.5L Gasoline S = 4.0L Gasoline 9 Check Digit 10 Model Year X = 1999 11 Assembly Plant L = Toledo #1 12 thru 17 Vehicle Build Sequence XJ INTRODUCTION 1

VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 1)is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all appli- cable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin. The label is located on the driver-side door shut- face. BODY CODE PLATE LOCATION AND DECODING A metal body code plate is attached to the left (driver’s side) of the dash panel in the engine com- partment. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate (Fig. 2). The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued). When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap. BODY CODE PLATE—LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13, 14, AND 15 Open Space DIGITS 16, 17, AND 18 Car Line Shell • XJT = Cherokee 2WD (LHD) • XJJ = Cherokee 4WD (LHD) • XJB = Cherokee 2WD (RHD) • XJU = Cherokee 4WD (RHD) DIGIT 19 Price Class • L = Cherokee (All) DIGITS 20 AND 21 Body Type • 72 = 2–Door • 74 = 4–Door BODY CODE PLATE—LINE 2 DIGITS 1,2, AND 3 Paint Procedure DIGIT 4 Open Space DIGITS 5 THROUGH 8 Primary Paint Refer to Group 23, Body for color codes. DIGIT 9 Open Space Fig. 1 Vehicle Safety Certification Label—Typical Fig. 2 Body Code Plate Decoding 2 INTRODUCTION XJ GENERAL INFORMATION (Continued)

DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • EPE = 2.5 L 4 cyl. MPI Gasoline • ERH = 4.0L 6 cyl. MPI Gasoline BODY CODE PLATE—LINE 1 DIGITS 1, 2, AND 3 Transmission Codes • DDQ = AX5 5–speed Manual • DGS = AW4 4–speed Automatic DIGIT 4 Open Space DIGIT 5 Market Code • B = International • C = Canada • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) Refer to Vehicle Identification Number (VIN) para- graph for proper breakdown of VIN code. INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig. 3 XJ INTRODUCTION 3 GENERAL INFORMATION (Continued)

FASTENER IDENTIFICATION FASTENER IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt/nut threads are not the same. The difference is described in the Thread Notation chart (Fig. 4). GRADE/CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 12.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts. Fig. 4 Thread Notation Chart – SAE and Metric 4 INTRODUCTION XJ GENERAL INFORMATION (Continued)

FASTENER IDENTIFICATION XJ INTRODUCTION 5 GENERAL INFORMATION (Continued)

FASTENER STRENGTH 6 INTRODUCTION XJ GENERAL INFORMATION (Continued)

FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoilt. Follow the manufactures recommenda- tions for application and repair procedures. METRIC SYSTEM WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL IJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage metric fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification should be used. The metric system is based on quantities of one, ten, one hundred, one thousand and one million (Fig. 5). The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. Refer to the Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) CONVERSION FORMULAS AND EQUIVALENT VALUES Fig. 5 Metric Prefixes XJ INTRODUCTION 7 GENERAL INFORMATION (Continued)

METRIC CONVERSION 8 INTRODUCTION XJ GENERAL INFORMATION (Continued)

TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifi- cations Chart for torque references not listed in the individual torque charts. TORQUE SPECIFICATIONS XJ INTRODUCTION 9 GENERAL INFORMATION (Continued)

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1999 Jeep Cherokee Service & Repair Manual

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