Jeep Wrangler TJ 2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Generation Code: TJ 👋 Introduction Market Position Market Segment: Compact SUV, Off-Road Vehicle Competitive Analysis Key Competitors: Toyota Tacoma, Nissan...

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标签: 2004 Car Cars Jeep Misc Wrangler TJ

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Generation Code:

👋 Introduction

Market Position

Market Segment:

Compact SUV, Off-Road Vehicle

Competitive Analysis

Key Competitors:

Toyota Tacoma, Nissan Frontier, Land Rover Defender (earlier models)

Key Features

Design Philosophy:

Rugged, trail-capable, open-air experience

Vehicle Identity:

Iconic Jeep capability, solid axles, removable doors and top

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Factory Service Repair

Page Count

Estimated Pages:

Hundreds (Printable)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable (Likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnosis, repair, overhaul for all TJ powertrain options

Transmission:

Service and repair for manual and automatic transmissions

Drivetrain:

Axles, differentials, transfer case, driveshafts, CV joints

Suspension:

Front and rear suspension components, steering linkage

Brakes:

Hydraulic system, ABS (if equipped), disc and drum brake service

Electrical:

Wiring diagrams, component testing, battery, charging, ignition systems

Body And Frame:

Body panel repair, interior trim, convertible top service

HVAC:

Air conditioning, heating, ventilation system diagnosis and repair

Fuel System:

Fuel pump, injectors, lines, evaporative emissions control

Cooling System:

Radiator, water pump, thermostat, hoses, fan

Exhaust System:

Mufflers, catalytic converter, pipes, hangers

Emissions Control:

EGR, PCV, O2 sensors, evaporative emissions system

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements

Troubleshooting:

Diagnostic charts and procedures for common and uncommon faults

Repair:

Step-by-step repair instructions for all major components

Overhaul:

Complete engine and transmission rebuild procedures

Diagnostics:

Fault code interpretation, component testing, circuit analysis

Installation:

Component replacement and installation guidelines

Specifications:

Torque values, clearances, alignments, fluid capacities

Technical Depth

Depth:

Comprehensive, from basic checks to complete engine rebuilds

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Printability:

High-resolution, printable pages

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Text Search:

Searchable text for quick information retrieval

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

4.0L Inline-6 (G/E) - PowerTech

Engine Displacement Primary:

3952 cc (241 cubic inches)

Horsepower Primary:

190 hp @ 4,600 rpm

Torque Primary:

235 lb-ft @ 3,200 rpm

Optional Engine

Engine Code Optional:

2.4L Inline-4 (D) - World Gas Engine

Engine Displacement Optional:

2429 cc (148 cubic inches)

Horsepower Optional:

150 hp @ 5,200 rpm

Torque Optional:

177 lb-ft @ 3,800 rpm

Fuel System

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Cooling System

Coolant Type:

Chrysler/Mopar HOAT (50/50 mixture with distilled water)

🔧 Transmission

Standard

Transmission Type Standard:

6-Speed Manual (NV3550)

Optional

Transmission Type Optional:

4-Speed Automatic (42RLE)

Features

Transfer Case:

Selec-Trac NV242 (Command-Trac NP231 also common)

Fluid Specifications

Manual Transmission Fluid:

NV3550: Mopar Manual Transmission Lubricant (MS-9224) or equivalent, 2.1 liters (2.2 qts)

Automatic Transmission Fluid:

42RLE: ATF+4 (MS-9602), 7.2 liters (7.6 qts) total capacity

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width:

66.5 inches (1689 mm)

Height:

71.7 inches (1821 mm)

Ground Clearance:

~9.7 inches (246 mm) (varies with tire size/suspension)

Weights

Curb Weight Std Engine:

Approx. 3,500 lbs (1588 kg)

Towing Capacity:

2,000 lbs (907 kg)

Payload Capacity:

Approx. 800-900 lbs (363-408 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3 stars (Class II SUV)

Active Features

Optional on most models, standard on some later TJ's

Traction Control:

Not generally available on 2004 TJ models

Passive Features

Airbags:

Driver and Passenger Front Airbags

Seatbelts:

Three-point front, two-point rear (lap belts)

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional Infinity speaker system

Navigation:

Not available from factory

Driver Assistance

Cruise Control:

Optional

Connectivity

Bluetooth:

Not available from factory

🔧 Maintenance

Service Intervals

Oil Change Interval Severe:

3,000 miles (4,800 km) or 3 months

Oil Change Interval Normal:

5,000-7,500 miles (8,000-12,000 km) or 6-12 months (depending on oil used)

Air Filter Replacement:

Every 15,000 miles (24,000 km) or as needed

Spark Plug Replacement 4.0L:

Approx. 100,000 miles (160,000 km) (Champion Copper Plus or equivalent)

Fluid Specifications

Engine Oil Capacity 4.0L:

5 US quarts (4.7 liters) with filter (API SG or higher, 10W-30 recommended)

Engine Oil Capacity 2.4L:

5 US quarts (4.7 liters) with filter (API SG or higher, 5W-30 recommended)

Coolant Capacity:

Approx. 10.5 quarts (9.9 liters) for 4.0L, 7.7 quarts (7.3 liters) for 2.4L

Brake Fluid:

DOT 3

Known Issues

Common Issues 4.0L:

Oil leaks (rear main seal, valve cover gasket), occasional death wobble (steering/suspension related), exhaust manifold cracks

Common Issues 2.4L:

Oil consumption, head gasket issues in some cases

Common Issues Transmission:

NV3550: Clutch wear, 2WD models may experience rear main seal issues from output shaft. 42RLE: Occasional solenoid issues, torque converter shudder

Common Issues Drivetrain:

U-joint wear, differential seal leaks, transfer case chain stretch

Common Issues Suspension:

Worn control arm bushings, track bar issues (leading to death wobble), worn ball joints

Common Issues Electrical:

Cracked wiring harnesses (especially near engine bay), failing instrument cluster components, C101 connector issues

📚 Vehicle History

Brand Heritage

Brand Legacy:

Jeep's long history of off-road vehicle development dating back to WWII

Model Evolution

Tj Introduction:

Introduced for the 1997 model year, replacing the YJ Wrangler

Tj Key Innovations:

Return to coil springs for improved ride and articulation, elimination of leaf springs

Tj Updates 2004:

Minor interior revisions, potential for improved NV3550 transmission in later years, optional 17" wheels

Production

Production Location:

Toledo, Ohio, USA

Production Years Tj:

1997-2006

🏆 Awards & Recognition

Recognitions

Off Road Capability:

Consistently recognized for superior off-road performance in its class

Ratings

Consumer Reports:

Varied ratings depending on year and powertrain, often praised for capability but criticized for reliability and ride comfort

Certifications

Emissions Certifications:

Meets EPA and CARB standards for model year 2004