Engine:
Detailed diagnostics, repair, overhaul, component testing
Fuel System:
Fuel injection system, fuel pump, injectors, lines, evaporative emissions
Ignition System:
Spark plugs, ignition coils, ECU control, timing
Transmission:
Manual gearbox: clutch, linkage, internal components, fluid maintenance
Drivetrain:
Transfer case operation, driveline components, axle assemblies
Suspension:
Front and rear suspension, springs, shocks, control arms, bushings
Steering:
Power steering system, steering column, tie rods, alignment
Braking System:
Front and rear disc brakes, ABS (if equipped), parking brake, fluid system
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, diagnostics
Bodywork:
Body panel removal/installation, interior trim, doors, hood, tailgate, convertible top
HVAC:
Air conditioning system, heater core, blower motor, climate control
Wheels Tires:
Tire specifications, rotation, balancing, wheel torque
Routine Maintenance:
Oil changes, filter replacements, fluid checks, lubrication
Troubleshooting:
Diagnostic procedures for all major systems, symptom-based guides
Component Replacement:
Step-by-step instructions for replacing parts across all systems
Engine Rebuild:
Complete engine overhaul procedures, including internal component measurements
Electrical Diagnostics:
Detailed wiring diagrams, component testing, troubleshooting logic
Brake Service:
Pad replacement, rotor machining/replacement, caliper service, bleeding
Suspension Repair:
Shock absorber replacement, bushing replacement, alignment procedures
Depth:
Comprehensive: from basic maintenance to complete system overhauls and diagnostics
Engine Code:
4.0L I6 (Optional: 2.5L I4)
Horsepower 40L:
190 hp @ 4600 rpm
Torque 40L:
235 lb-ft @ 3200 rpm
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Spark Plug Gap:
0.040-0.045 inches (typically Champion Copper Plus, specific part numbers provided in manual)
Oil Capacity:
6 US quarts (5.7 liters) with filter for 4.0L I6
Recommended Oil Viscosity:
SAE 10W-30 (check owner's manual for specific climate variations)
Type:
NV3550 5-Speed Manual Transmission
Type:
42RLE 4-Speed Automatic Transmission (less common on early TJ, but available)
Transfer Case:
231J Command-Trac (part-time, 2-high, 4-high, neutral, 4-low)
Manual Transmission Fluid:
NV3550 requires MS-9224 compliant fluid (e.g., Mopar Manual Transmission Lubricant)
Automatic Transmission Fluid:
ATF+4 (MS-9602) for 42RLE
NHTSA Rollover Rating:
3 out of 5 stars (typical for body-on-frame SUVs of the era, emphasis on driver awareness)
ABS:
Available on some models, primarily rear-wheel ABS on earlier TJs, 4-wheel ABS later
Airbags:
Driver and passenger front airbags
Roll Cage:
Integrated sport bar (roll cage) for enhanced occupant protection
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for exact recommendations based on driving conditions)
Tire Rotation:
Every 5,000-7,500 miles
Transmission Fluid Change:
Manual: check condition, typically every 30,000-60,000 miles. Automatic: every 30,000-50,000 miles.
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 5/150 Formula (or equivalent HOAT)
Power Steering Fluid:
MS-5944 (Mopar Power Steering Fluid or equivalent)
Common Problems 1:
Cracked exhaust manifolds (4.0L I6), leaks from the rear main seal, clutch wear, front axle U-joint failure
Common Problems 2:
Blend door actuator failure (HVAC), water pump leaks, radiator leaks, minor electrical gremlins
