Purpose:
A comprehensive resource for Jeep Wrangler TJ owners and independent workshops to perform repairs and maintenance.
Value Proposition:
Provides dealership-level technical information at a fraction of the cost, empowering DIY repairs and saving money.
Content Focus:
Focuses on practical, step-by-step guidance with clear illustrations for ease of understanding, suitable for all skill levels.
Primary Coverage:
Comprehensive service and repair for the 2004 Jeep Wrangler TJ
Secondary Coverage:
Includes maintenance, diagnostics, troubleshooting, and specifications for all major vehicle systems.
Estimated Page Count:
Likely 1000+ pages based on typical workshop manual density.
Type:
Service Repair Workshop Manual
Engine:
Detailed coverage of the 4.0L Power Tech I6 engine, including diagnosis, repair, and overhaul procedures.
Fuel And Emissions:
Injection system, ignition system, fuel delivery, exhaust system, emissions control components.
Drivetrain:
Clutch, manual and automatic transmissions (e.g., NV3550, NV241OR transfer case), driveshafts, differentials, axles.
Suspension And Steering:
Front and rear suspension components, springs, shock absorbers, steering linkage, power steering system.
Braking System:
Front and rear brake systems (disc/drum), ABS components (if equipped), hydraulic lines, parking brake.
Wheels And Tires:
Wheel specifications, tire pressure recommendations, mounting procedures.
Electrical System:
Battery, charging system, starting system, lighting, instrumentation, body electricals, wiring diagrams.
Bodywork And Chassis:
Body panels, doors, interior trim, seats, bumpers, frame, corrosion protection.
Climate Control:
Air conditioning system, heater, ventilation, cabin air filters.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, fluid checks, spark plug replacement.
Repair And Overhaul:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Diagnostics And Troubleshooting:
Systematic diagnostic procedures, fault finding charts, and troubleshooting guides for common issues.
Technical Data:
Torque specifications, fluid capacities, technical data, and specifications for all major components.
Diagrams And Illustrations:
Detailed step-by-step diagrams, exploded views, and wiring schematics for clear guidance.
Depth:
Extremely detailed, covering basic to advanced repair and overhaul procedures, including engine rebuilding.
Engine Type:
4.0L Power Tech Inline 6-Cylinder (I6)
Engine Code:
Typically referred to as the '4.0L' or 'AMC 242'
Horsepower Approx:
190 hp @ 4,600 rpm
Torque Approx:
235 lb-ft @ 3,200 rpm
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Spark Plugs:
Champion Copper Plus (e.g., RC12ECC) or equivalent, gap 0.035 inches.
Engine Oil Type:
SAE 5W-30 (preferred) or SAE 10W-30, meeting API SN or similar specification.
Engine Oil Capacity:
5.7 US quarts (5.4 liters) with filter change.
Manual Transmission:
New Venture Gear NV3550 5-speed manual transmission.
Automatic Transmission:
Optional 42RLE 4-speed automatic transmission.
Transfer Case:
New Venture Gear NV241OR 'Rock-Trac' heavy-duty part-time four-wheel-drive transfer case (standard on Rubicon).
Transfer Case Fluid:
Mopar NV241OR Transfer Case Lubricant or equivalent SAE 75W-90 synthetic gear oil.
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant or equivalent SAE 75W-90 synthetic gear oil.
Automatic Transmission Fluid:
Mopar ATF+4 (MS-9602) or equivalent.
Oil Change Interval:
Every 3,000-7,500 miles (4,800-12,000 km) or 6 months, depending on driving conditions and oil type used.
Tire Rotation Interval:
Every 5,000-7,500 miles (8,000-12,000 km).
Coolant Flush Interval:
Every 30,000-50,000 miles (48,000-80,000 km) or 3-5 years, using Mopar OAT (Organic Additive Technology) coolant.
Coolant Type:
Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent ATF +4.
Common Problems:
Potential for rear main seal leaks, exhaust manifold cracks, heater core leaks, and frame rust (depending on climate).
Common Fixes:
Manual provides procedures for addressing these common issues, including seal replacement, manifold repair/replacement, and rust treatment.
Jeep Legacy:
Continuation of the iconic Jeep Wrangler lineage, known for its off-road capability and ruggedness.
Tj Generation:
The TJ generation (1997-2006) introduced coil spring suspension, a significant upgrade from the leaf springs of previous generations.
Manufacturing Location:
Toledo North Assembly Plant, Toledo, Ohio, USA.
