Vehicle Segment:
Compact/Mid-size SUV, Off-road focused vehicle.
Target Audience:
Off-road enthusiasts, Jeep owners performing DIY maintenance and repairs, restoration projects, professional mechanics.
Key Competitors Era:
Toyota Tacoma/4Runner, Ford Bronco (earlier generations), Land Rover Defender, Suzuki Samurai/Vitara.
Usp Vehicle:
Renowned off-road capability, iconic design, extensive aftermarket support, simple yet robust mechanicals.
Manual Benefit:
Empowers owners to perform a wide range of maintenance and repair tasks, reducing reliance on costly shop labor and increasing vehicle longevity.
Manual Value Proposition:
Comprehensive, factory-level technical data provides accuracy and completeness for all service needs.
Covered Years:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Region Applicability:
North America (US, Canada, Mexico) and potentially other global markets with similar specifications.
Estimated Page Count:
Thousands (Typical for full factory service manuals, exact number not provided but implied by 'Complete Factory Service Repair Workshop Manual').
Manual Type:
Factory Service Manual / Workshop Manual / Repair Manual
Delivery Format:
Digital Download (Computer, Tablet, Smartphone)
Accessibility:
Instant download, no expiry dates.
Powertrain:
Engine mechanical (4.0L I6, 4.7L V8 - if applicable for specific TJ year/market, though 4.0L is primary), Fuel system, Ignition system, Exhaust system, Cooling system, Engine control systems (ECU/PCM), Manual transmission (AX-5, NV3550), Automatic transmission (AW4, 42RLE), Transfer case (NP231, NV241OR 'Rubicon'), Clutch system, Drivelines, Axles (Dana 30 front, Dana 35/44 rear).
Chassis:
Suspension (Solid axles front/rear, coil springs), Steering system (power steering, steering linkage), Brakes (disc front/rear, ABS components), Wheels and tires.
Electrical And Electronics:
Wiring diagrams, Battery system, Starting system, Charging system, Lighting (headlights, taillights, interior), Instrumentation and warning indicators, Power windows, Power locks, Audio system, HVAC system controls, Engine control module (ECM) / Powertrain control module (PCM), Body control module (BCM).
Body And Interior:
Body panels, Doors, Hood, Tailgate, Seats, Interior trim, Convertible top, Hardtop, Bumpers, Frame (body-on-frame construction).
Maintenance:
Oil changes, Filter replacements, Fluid level checks and top-offs, Tire rotation and pressure checks, Spark plug replacement, Belt inspections and replacement, Brake pad and rotor replacement, Battery maintenance.
Diagnostics And Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-based troubleshooting guides, Electrical circuit testing, Mechanical component diagnosis.
Repair And Rebuild:
Engine assembly/disassembly, Transmission overhaul, Clutch replacement, Suspension component replacement, Brake system repair, Steering system repair, Electrical component replacement, Body panel repair.
Specifications And Procedures:
Torque specifications for fasteners, Fluid capacities and types, Jiggle valve locations, Pinout diagrams for connectors, Alignment procedures, Diagnostic tool usage.
Depth Of Coverage:
Comprehensive. Covers routine maintenance, detailed diagnostics, component-level repair, and full system overhauls, mirroring factory-issued service information.
Engine Code:
AMC 242 / PowerTech
Engine Configuration:
Inline 6-Cylinder (I6)
Displacement:
4.0 Liters (242 cubic inches)
Bore X Stroke:
3.875 in x 3.580 in (98.4 mm x 91.0 mm)
Compression Ratio:
8.8:1 (Typical)
Horsepower Rating:
Approx. 181 hp @ 4,200 rpm (Varies slightly by year)
Torque Rating:
Approx. 222 lb-ft @ 3,200 rpm (Varies slightly by year)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane or higher recommended)
ECU PCM:
Chrysler/Jeep PCM (e.g., NGC or earlier variants depending on year)
Ignition System:
Distributorless Ignition System (DIS) with Crankshaft Position Sensor (CKP) and Camshaft Position Sensor (CMP)
Cooling Type:
Pressurized liquid cooling system
Transmission Type Manual:
New Venture Gear NV3550 (5-speed manual) / AX-5 (earlier models)
Transmission Type Automatic:
Chrysler 42RLE (4-speed automatic) / AW4 (earlier models)
Transfer Case Standard:
New Process NP231 Command-Trac (2WD/4WD part-time)
Transfer Case Optional:
New Venture NV241OR (Rock-Trac - 4WD full-time, locking front differential)
Manual Transmission Fluid:
GL-3 or GL-4 gear oil, SAE 75W-90 (e.g., Mopar Manual Transmission Lubricant)
Automatic Transmission Fluid:
ATF+4 (Chrysler specification, Mopar Automatic Transmission Fluid)
Transfer Case Fluid:
Mopar NV241 Transfer Case Lubricant or equivalent SAE 75W-90 synthetic gear oil.
Wheelbase:
93.4 inches (2372 mm) for short wheelbase (2-door)
Overall Length:
150.4 inches (3820 mm) for short wheelbase (2-door)
Overall Width:
66.7 inches (1694 mm)
Overall Height:
72.7 inches (1847 mm) (with soft top, varies)
Curb Weight:
Approx. 3,400 - 3,700 lbs (1542 - 1678 kg) depending on configuration
Gross Vehicle Weight Rating:
Approx. 4,850 - 5,200 lbs (2199 - 2359 kg)
Cargo Volume Behind Front Seats:
Approx. 43.4 cubic feet (1.23 m³) (with rear seats folded)
Cargo Volume Behind Rear Seats:
Approx. 14.8 cubic feet (0.42 m³)
NHTSA Rollover Resistance:
3-star rating (typical for this era and vehicle type)
IIHS Crash Test Ratings:
Varies by specific test and year, generally moderate performance for its class.
ABS:
Optional on many models, standard on some later models or specific trims.
Traction Control:
Limited availability, often tied to ABS systems on specific trims/years.
Airbags:
Driver and passenger front airbags.
Seatbelts:
3-point front seat belts, lap belts for rear passengers.
Roll Cage:
Integrated roll cage structure for enhanced occupant protection in rollovers.
Audio System Options:
Factory AM/FM/CD players, optional premium sound systems (e.g., Infinity).
Navigation:
Not typically factory-installed during this era; aftermarket solutions common.
Cruise Control:
Available on most models.
Stability Control:
Not available on most TJ models; some later models may have incorporated basic traction control tied to ABS.
Bluetooth:
Not factory-equipped; aftermarket head units required.
Oil Change Interval:
Every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions and oil type.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (depending on plug type - copper vs. platinum/iridium).
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years.
Engine Oil Spec:
API Certified SAE 10W-30 (preferred for 4.0L) or SAE 5W-30 for colder climates. Refer to owner's manual for exact specification.
Engine Oil Capacity:
6 US quarts (5.7 Liters) with filter change for 4.0L engine.
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant (typically orange or red) mixed 50/50 with distilled water.
Engine Common Problems:
Oil filter housing leaks, exhaust manifold cracks (especially on 4.0L), piston slap on cold starts, radiator leaks, rear main seal leaks.
Transmission Common Problems:
Clutch wear (manual), torque converter shudder (automatic), transfer case chain stretch or wear.
Chassis Common Problems:
Death wobble (worn steering/suspension components), rust on frame and body mounts, worn ball joints and tie rod ends, worn U-joints.
Electrical Common Problems:
Instrument cluster failure, blower motor resistor failure, intermittent electrical connections, PCM issues.
Jeep Legacy:
Jeep has a storied history in military vehicles and off-road prowess dating back to WWII.
Tj Introduction:
Introduced for the 1997 model year as a successor to the YJ Wrangler.
Tj Distinguishing Features:
Returned to round headlights (unlike the YJ's square headlights), introduced coil springs instead of leaf springs for improved ride quality and articulation.
Tj Significant Updates:
Introduction of the Rubicon trim (2003) with Dana 44 axles, locking differentials, and a lower transfer case ratio; introduction of the 42RLE automatic transmission.
Production Period:
1997 - 2006
Manufacturing Plant:
Toledo, Ohio, USA
