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Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Model Code: JK (2007-2018), JL (2018-Present) Applicable Years: 2004 Onwards Manual Product Name: Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS Codes Chassis...
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Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Model Code:
JK (2007-2018), JL (2018-Present)
Applicable Years:
2004 Onwards
Manual Product Name:
Jeep WRANGLER Workshop Repair Manual 2004 ONWARDS
Codes
Chassis Codes Covered:
TJ (up to 2006), JK, JL
👋 Introduction
Market Position
Segment:
Compact/Mid-size SUV, Off-Road Vehicle
Target Audience:
Off-road enthusiasts, adventure seekers, Jeep owners requiring detailed repair information.
Competitive Analysis
Key Competitors:
Toyota 4Runner, Ford Bronco, Land Rover Defender, Nissan Xterra.
Key Features
Off Road Capability:
Renowned for its segment-leading off-road prowess with features like solid axles (older generations), 4x4 systems, and high ground clearance.
Iconic Design:
Distinctive seven-slot grille, round headlights, exposed hinges, and removable doors/roof contribute to its unique identity.
📋 Manual Details
Coverage Areas
Coverage Overview:
Comprehensive workshop service and repair for all systems.
Page Count
Estimated Page Count:
Extensive, typically 2000+ pages depending on variant and year.
Manual Type
Manual Type:
Official Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling system.
Engine Performance:
Fuel injection, ignition system, emissions control, turbocharging (if applicable).
Transmission Manual:
Clutch, gearbox assembly, internal components, linkages, fluid service.
Transmission Automatic:
Transmission assembly, torque converter, valve body, electronic controls, fluid service.
Drivetrain:
Transfer case (NVG/Rock-Trac/Command-Trac), front and rear drive shafts, differentials, axle assemblies (Dana 30, Dana 44), axle shafts, U-joints.
Suspension:
Front and rear suspension systems (coil springs, multi-link solid axle, independent front suspension for JL), shock absorbers, control arms, sway bars, bushings.
Steering:
Power steering system, steering gear, steering column, tie rods, drag links, steering stabilizer.
Brakes:
Front and rear brake systems (disc/disc), ABS, traction control, brake calipers, rotors, pads, lines, master cylinder, brake booster, parking brake.
Electrical System:
Battery, charging system (alternator), starting system, wiring diagrams, fuse box locations, relay assignments.
Lighting:
Headlights, taillights, turn signals, interior lighting, fog lights, wiring and bulb specifications.
HVAC:
Heating, ventilation, and air conditioning system (compressor, condenser, evaporator, blower motor, controls, refrigerant recharge).
Body And Chassis:
Body panels, doors, hood, fenders, bumpers, frame, VIN decoding, interior trim, convertible top mechanism.
Restraints:
Airbag system, seat belts, SRS module, diagnostic procedures.
Infotainment And Electronics:
Radio, navigation system, speakers, power windows, power locks, keyless entry, instrument cluster, trailer brake controller (optional).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections.
Diagnostic Troubleshooting:
Step-by-step guides for identifying and resolving common and complex issues across all systems, including OBD-II codes.
Repair And Rebuild:
Detailed procedures for component removal, disassembly, inspection, repair, reassembly, and installation.
Component Replacement:
Instructions for replacing common wear items and major components.
Specifications And Tolerances:
Torque specifications, clearances, fluid capacities, and other critical technical data.
Wiring Diagrams:
Comprehensive, labeled wiring schematics for all electrical systems.
Technical Depth
Depth Level:
Professional-grade, covering everything from basic adjustments to complete powertrain and chassis overhauls.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Print Quality
Searchability:
Fully searchable text, allowing quick access to specific information.
Image Resolution:
High-resolution diagrams and illustrations suitable for printing.
Binding Type
Binding Method:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 2004 2006 Tj:
4.0L (3952cc) Straight-6 "PowerTech" I6 OHV
Engine 2007 2011 Jk:
3.8L (3778cc) V6 "Triton" OHV
Engine 2012 2018 Jk:
3.6L (3604cc) V6 Pentastar VVT
Engine 2018 Jl:
3.6L (3604cc) V6 Pentastar VVT, 2.0L (1995cc) Turbocharged I4 "Hurricane"
Performance
Hp 4.0L I6:
Approx. 190 hp @ 4600 rpm
Torque 4.0L I6:
Approx. 235 lb-ft @ 3200 rpm
Hp 3.8L V6:
Approx. 202 hp @ 5200 rpm
Torque 3.8L V6:
Approx. 237 lb-ft @ 4000 rpm
Hp 3.6L V6 Pentastar:
Approx. 285 hp @ 6400 rpm
Torque 3.6L V6 Pentastar:
Approx. 260 lb-ft @ 4800 rpm
Hp 2.0L Turbo I4:
Approx. 270 hp @ 5250 rpm
Torque 2.0L Turbo I4:
Approx. 295 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) / Direct Injection (DI) for some Turbo models
Fuel Type:
Unleaded Gasoline (87 Octane minimum recommended)
🔧 Transmission
Standard
Transmission Tj:
5-Speed Manual (NV1500/NV3550)
Transmission Jk Early:
6-Speed Manual (NSG370)
Transmission Jk Late Jl:
6-Speed Manual (NSG370 / DTC NV3550)
Optional
Transmission Tj Auto:
4-Speed Automatic (42RLE)
Transmission Jk Auto:
4-Speed Automatic (42RLE) until 2011, 5-Speed Automatic (W5A580/NAG1) 2012-2018, 8-Speed Automatic (850RE) JL
Features
Transfer Case Tj:
Command-Trac NV231, Selec-Trac NV242 (optional)
Transfer Case Jk:
Command-Trac NV241, Rock-Trac NV241OR
Transfer Case Jl:
Selec-Trac Full-Time 4WD, Command-Trac Part-Time 4WD, Rock-Trac Full-Time 4WD
📐 Dimensions
Exterior
Wheelbase 2Dr:
95.4 inches (2423 mm)
Wheelbase 4Dr Jk Jl:
116.0 inches (2946 mm)
Overall Length 2Dr:
Approx. 160-170 inches (4064-4318 mm)
Overall Length 4Dr Jk Jl:
Approx. 179-184 inches (4547-4674 mm)
Cargo
Cargo Volume Behind Rear Seat 2Dr:
Approx. 13.4 cu ft (379 L)
Cargo Volume Behind Rear Seat 4Dr Jk Jl:
Approx. 31.5 cu ft (892 L)
Weights
Curb Weight 2Dr:
Approx. 3,500 - 4,000 lbs (1588 - 1814 kg)
Curb Weight 4Dr Jk Jl:
Approx. 4,200 - 4,800 lbs (1905 - 2177 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Varies by model year and configuration, often 3 or 4 stars for 2-door, 4 stars for 4-door (check specific year).
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Traction Control System (TCS)
Esc:
Standard Electronic Stability Control (ESC) - introduced with JK generation
Hill Start Assist:
Available on later models (JK/JL)
Passive Features
Airbags:
Front airbags, side curtain airbags (available/standard depending on year/trim)
Seat Belts:
3-point seat belts with pretensioners
💡 Technology Features
Infotainment
Infotainment Systems Jk:
Uconnect systems with touchscreens (5", 6.5", 8.4" depending on year/trim), SiriusXM Satellite Radio, optional Navigation.
Infotainment Systems Jl:
Updated Uconnect systems (7", 8.4") with Apple CarPlay and Android Auto integration, SiriusXM Traffic and Travel Link.
Driver Assistance
Driver Assistance Features:
Available features include Blind-Spot Monitoring, Rear Cross-Path Detection, ParkView Rear Back-Up Camera, Forward Collision Warning (late models), Adaptive Cruise Control (late models).
Connectivity
Connectivity Options:
Bluetooth connectivity for hands-free calling and audio streaming, USB ports, available Wi-Fi Hotspot (JL).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specific engine).
Tire Rotation Interval:
Every 7,500 miles (12,000 km) or as part of oil change.
Transmission Fluid Change Manual:
Inspect every 30,000 miles (48,000 km); change as needed or every 60,000-100,000 miles (96,000-160,000 km) depending on usage.
Transmission Fluid Change Automatic:
Inspect every 30,000 miles (48,000 km); change typically every 60,000 miles (96,000 km) for normal use, or sooner for severe use (towing, off-roading).
Fluid Specifications
Engine Oil 4.0L I6:
SAE 10W-30 API SG or higher
Engine Oil 3.6L Pentastar:
SAE 0W-20 API SN or SP, MS-6395
Engine Oil 2.0L Turbo:
SAE 0W-20 API SP, MS-13375
Coolant:
Mopar OAT (Organic Additive Technology) HOAT antifreeze (MS-9769) or equivalent, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 compatible brake fluid
Transfer Case Fluid:
Mopar NV241G Heavy Duty Lubricant or equivalent (check specific transfer case type)
Axle Differential Fluid:
SAE 75W-90 GL-5 gear oil. Friction modifier (Mopar LS additive or equivalent) required for limited-slip differentials.
Known Issues
Death Wobble Jk:
A common term for severe steering shimmy, often related to worn steering and suspension components (track bar, ball joints, tie rods, steering damper).
Oil Cooler Leaks Pentastar:
Potential for oil leaks from the oil filter housing and cooler assembly on Pentastar V6 engines.
Evaporator Case Leaks:
Water leaking into the cabin from the HVAC evaporator case, often due to clogged drain tubes.
Clutch Release Bearing Nsg370:
Some manual transmissions can experience noise from the clutch release bearing.
📚 Vehicle History
Brand Heritage
Jeep Origin:
Roots in military vehicles (Willys MB) during World War II, renowned for ruggedness and off-road capability.
Model Evolution
Tj Wrangler:
1997-2006. Introduced coil springs for a more comfortable ride, retained solid axles. Key features included the 4.0L inline-6 engine.
Jk Wrangler:
2007-2018. Major redesign. Introduced a unibody construction for the JK (though still considered body-on-frame by many), 4-door Unlimited model, modern amenities, and electronic stability/traction control. Engine options changed over its lifespan.
Jl Wrangler:
2018-Present. Further evolution. Lighter materials, more aerodynamic design, new engine options (2.0L Turbo, 3.0L EcoDiesel, 4xe Plug-in Hybrid), available independent front suspension (4xe models), and updated technology.
Production
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently recognized for off-road capability by automotive publications and enthusiast groups.
Segment Awards:
Often cited as a leader in its class for capability and iconic status.
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