Positioning:
The definitive guide for maintaining and repairing the iconic Jeep Wrangler TJ generation
Advantage:
Provides dealer-level information, surpassing generic repair guides in detail and accuracy
Feature 1:
Comprehensive system coverage
Feature 2:
Detailed diagnostic procedures
Feature 3:
Extensive torque specifications and clearances
Feature 4:
Essential for owners who perform their own maintenance and repairs
Engine:
All aspects including diagnostics, overhaul, performance tuning
Transmission:
Manual and Automatic transmission repair, clutch, drivetrain
Suspension:
Front and rear suspension, shock absorbers, springs, steering linkage
Brakes:
Front and rear brake systems, ABS, hydraulic components
Electrical:
Wiring diagrams, lighting, ignition, charging system, starter, accessories
Chassis:
Frame, body, doors, hoods, security systems
HVAC:
Heating, Ventilation, and Air Conditioning system
Fuel System:
Fuel tank, pump, injectors, emissions control
Cooling System:
Radiator, water pump, thermostat, coolant specifications
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks
Diagnostics:
Troubleshooting guides, DTC interpretation, diagnostic procedures
Repair:
Component removal, installation, adjustment, and overhaul procedures
Specifications:
Torque specifications, clearances, tolerances, fluid capacities
Wiring Diagrams:
Detailed electrical circuit diagrams for all systems
Depth:
Comprehensive, covering dealer-level diagnostics and repairs
Digital Format:
PDF, often searchable and printable
Print Quality:
High-resolution diagrams and clear text (for printed versions)
Binding Type:
Spiral-bound or perfect-bound (for printed versions)
Paper Type:
Durable paper stock suitable for workshop environments (for printed versions)
Engine Type:
Inline 6-cylinder, Overhead Valve (OHV)
Engine Code:
AMC 242 (4.0L)
Displacement:
3957 cc (242 cubic inches)
Bore X Stroke:
3.875 in x 3.562 in (98.4 mm x 90.5 mm)
Compression Ratio:
8.75:1
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Ignition System:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or distributor-based systems
Horsepower Est:
190 hp @ 4600 rpm
Torque Est:
235 lb-ft @ 3200 rpm
Fuel Type:
Unleaded gasoline (87 octane recommended)
Fuel Tank Capacity:
15 US gallons (57 liters)
Emissions Control:
Catalytic converter, EGR (Exhaust Gas Recirculation), On-Board Diagnostics II (OBD-II)
Transmission Type:
5-Speed Manual Transmission (NV3550)
Transmission Type:
4-Speed Automatic Transmission (42RLE)
Transfer Case:
Command-Trac NV241 GII (Part-time, 2-High, 4-High, Neutral, 4-Low)
Clutch Type:
Dry single plate, hydraulically actuated (for manual)
Transmission Fluid Manual:
Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4 rated fluid)
Transmission Fluid Automatic:
Mopar ATF+4 (MS-9602) or equivalent
Audio System:
Factory AM/FM/CD player with optional Infinity sound system
Navigation:
Not typically factory-equipped, aftermarket options available
Driver Assistance Features:
Limited, primarily ABS. No electronic stability control or advanced driver aids.
Connectivity Features:
Basic, typically with auxiliary inputs for aftermarket devices.
Oil Change Interval:
Every 3,000 miles or 3 months (severe duty) or 6,000 miles or 6 months (normal duty)
Engine Oil Filter:
Mopar MO-899 or equivalent
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
Approximately 30,000 miles (refer to manual for specific type and gap)
Coolant Flush:
Every 30,000 miles or 24 months
Engine Oil Type:
SAE 10W-30 (API certified)
Engine Oil Capacity:
6 US quarts (5.7 liters) with filter
Coolant Type:
Mopar 5/150 Antifreeze/Coolant (or equivalent HOAT, ethylene glycol based)
Power Steering Fluid:
Mopar Power Steering Fluid (or equivalent ATF+4)
Common Issue 1:
Cracking of the exhaust manifold on the 4.0L engine
Common Issue 2:
Leaking valve cover gasket and oil pan gasket
Common Issue 3:
Radiator tank cracks or leaks
Common Issue 4:
Water pump failures
Common Issue 5:
Chrysler automotive fly-by-wire throttle issues (later models, less common on 2004)
Heritage:
Jeep's legacy of off-road capability and ruggedness, dating back to WWII
Tj Generation:
The TJ generation (1997-2006) introduced significant improvements over the YJ, including coil spring suspension and a more refined interior
Manufacturing Plant:
Toledo Complex, Toledo, Ohio, USA
