Positioning:
The Jeep Wrangler TJ is an iconic off-road vehicle, known for its ruggedness, capability, and classic design. This manual targets owners and technicians seeking in-depth knowledge for maintenance and repair.
Competitors:
Competes in the compact SUV/off-road segment, though its direct competitors are few due to its unique off-road focus. Often compared conceptually to vehicles like the Toyota 4Runner (earlier generations) or Land Rover Defender (discontinued in many markets).
Vehicle Features:
Solid front and rear axles, coil spring suspension, distinctive Jeep grille, removable doors and top, robust four-wheel-drive system (Command-Trac NV231 and optional Selec-Trac NV242 transfer cases).
Overall Coverage:
Complete Service Repair Manual
Model Coverage:
All TJ models and sub-models
Engine Coverage:
All engine variants for 1997-2003 TJ models
Estimated Page Count:
Varies by edition, typically 1000+ pages for comprehensive service manuals of this era.
Type:
Factory Service Manual (FSM) / Repair Manual
Format:
Digital (PDF) or Printed
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control systems.
Transmission:
Manual and Automatic transmissions, clutch, drivetrain components.
Suspension:
Front and rear suspension systems (solid axles, coil springs), steering system.
Brakes:
Brake system components (discs, drums, calipers, master cylinder, ABS if equipped), hydraulic lines.
Electrical:
Wiring diagrams, electrical components, starter, alternator, battery, lighting, accessories.
Body:
Body panels, doors, interior trim, seats, convertible top, frame inspection.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections.
Repair:
Component removal, installation, adjustment, and overhaul.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common issues and fixes.
Diagnostics:
OBD-II diagnostic codes, diagnostic procedures for various systems.
Depth:
Comprehensive: Covers everything from basic fluid checks to complete engine and transmission rebuilds.
Digital File Type:
PDF (typically search-enabled and printable)
Print Quality:
High-resolution images, clear diagrams, readable text (for printed versions).
Binding Type:
Comb binding, perfect binding, or ring-bound for printed versions for lay-flat use.
Paper Type:
Durable, often glossy or semi-gloss paper stock suitable for shop environments.
Engine 1 Name:
4.0L Inline 6-Cylinder (OHV)
Engine 1 Displacement:
3957 cc (242 cubic inches)
Engine 1 Bore X Stroke:
3.875 in x 3.414 in (98.4 mm x 86.7 mm)
Engine 1 Compression Ratio:
8.7:1
Engine 1 Horsepower:
182 hp @ 4600 rpm (1997-2002), 190 hp @ 4600 rpm (2003)
Engine 1 Torque:
220 lb-ft @ 3000 rpm (1997-2002), 235 lb-ft @ 3200 rpm (2003)
Engine 2 Name:
2.5L Inline 4-Cylinder (OHV)
Engine 2 Code:
AMC 150 (for early models)
Engine 2 Displacement:
2507 cc (153 cubic inches)
Engine 2 Horsepower:
119 hp @ 4700 rpm
Engine 2 Torque:
145 lb-ft @ 3000 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multiport Fuel Injection (SMPI)
Fuel Type:
Unleaded gasoline, 87 octane recommended
ECU:
Various Chrysler PCM (Powertrain Control Module) models depending on year and transmission.
Transmission 1 Type:
NV3550 5-speed Manual Transmission
Transmission 2 Type:
42RLE 4-speed Automatic Transmission (introduced later in the TJ run, replacing the 32RH)
Transmission 3 Type:
32RH 3-speed Automatic Transmission (earlier models)
Transfer Case Standard:
NV231 Command-Trac (Part-time, 2WD High, 4WD High, Neutral, 4WD Low)
Transfer Case Optional:
NV242 Selec-Trac (Full-time 4WD option, adds 4WD High Full-time)
Manual Transmission Fluid:
API GL-3 or GL-4, SAE 75W-90 (NV3550). Consult manual for exact specification.
Automatic Transmission Fluid:
ATF+4 (Chrysler spec) for 42RLE; ATF+3 for 32RH. Consult manual for exact specification.
Wheelbase:
93.4 inches (2372 mm) for standard models, 103.4 inches (2626 mm) for LWB Unlimited (LJ) models.
Length:
Approx. 160 inches (4064 mm) for short wheelbase, 170 inches (4318 mm) for LWB.
Width:
Approx. 73 inches (1854 mm)
Height:
Approx. 70 inches (1778 mm) with soft top
Curb Weight:
Approx. 3,200 - 3,800 lbs (1450 - 1725 kg) depending on configuration.
Max Towing Capacity:
2000 lbs (907 kg) for 6-cyl models, 1000 lbs (454 kg) for 4-cyl models.
NHTSA Rollover Resistance:
3 out of 5 stars (often rated based on center of gravity for SUVs of this era).
ABS:
Optional Anti-lock Braking System (ABS) available on rear wheels or all four wheels depending on year and configuration.
Airbags:
Driver and passenger front airbags standard.
Seatbelts:
Three-point seat belts with pretensioners for front occupants.
Audio System:
Basic AM/FM radio, optional CD player. Limited infotainment features compared to modern vehicles.
Display:
No central color display; simple radio head unit.
Cruise Control:
Optional cruise control available.
Phone Integration:
No built-in Bluetooth or smartphone integration; aftermarket solutions are common.
Oil Change Interval:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, whichever comes first. Synthetic oil may extend this. Consult manual.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs Replacement:
Approximately every 100,000 miles (160,000 km) for original equipment platinum plugs, but check specific type in manual.
Engine Oil Type:
SAE 10W-30 or 10W-40 for the 4.0L I6. Consult manual for precise specification.
Engine Oil Capacity:
6 US quarts (5.7 L) with filter for 4.0L I6.
Coolant Type:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) green coolant or equivalent.
Coolant Capacity:
Approx. 10.5 US quarts (9.9 L) for 4.0L I6.
Common Problems Engine:
Oil filter housing leaks, exhaust manifold cracks (4.0L), distributorless ignition system issues (coil packs).
Common Problems Transmission:
Clutch wear (manual), automatic transmission fluid leaks, torque converter issues.
Common Problems Suspension Steering:
Worn track bar bushings, ball joints, steering stabilizer issues, leaf spring wear (if equipped with aftermarket kits).
Common Problems Electrical:
Cracked wire harnesses, problematic TIPM (Totally Integrated Power Module) if later models had it, but TJ typically uses more distributed relays and fuses.
Common Problems Body:
Rust (especially frame, rocker panels, and floor pans), door hinge wear, tailgate issues, convertible top leaks.
Brand Legacy:
Jeep has a storied history dating back to World War II, renowned for its go-anywhere, do-anything ethos. The Wrangler is the direct descendant of the original Willys Jeep.
Tj Introduction:
The TJ Wrangler was introduced for the 1997 model year, replacing the YJ. It marked a significant engineering leap with the adoption of coil spring suspension and a unibody-like body-on-frame construction.
Tj Key Changes:
Key design elements include round headlights (a return to heritage), a wider track, and improved interior ergonomics. The Dana 30 front axle and Dana 35 or Dana 44 rear axles were common.
Manufacturing Location:
Toledo, Ohio, USA
Production Period:
1996 (for 1997 model year) through 2006
