🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Segment: Compact SUV / Off-road vehicle Reputation: Iconic off-road capability, ruggedness, and open-air driving experience. Competitive Analysis Competitors: Toyota 4Runner, Land Rover Defender, Ford Bronco (early generations), Suzuki Samurai. Key Features Design Philosophy: Body-on-frame construction, solid front and rear axles, removable doors and roof, short wheelbase for off-road maneuverability. Powertrain Options: Renowned for its robust powertrain options suited for demanding conditions. Target Audience: Enthusiasts seeking off-road capability, adventure seekers, and those who appreciate classic Jeep styling. 📋 Manual Details Coverage Areas Applicable Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Pages: Over 3000 Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, valve train, lubrication system, cooling system, fuel system (carburetor/injection), ignition system, emissions control. Transmission Drivetrain: Manual transmission (AX-5, NV3550), Automatic transmission (30/42RH, 42RLE), transfer case (NP231J, NV241OR), axles (Dana 30 front, Dana 35C rear, Dana 44 rear), drivelines, differentials. Brakes: Front disc brakes, rear drum/disc brakes, parking brake system, hydraulic system, ABS (if equipped). Suspension Steering: Front coil spring suspension with solid axle, rear leaf spring suspension with solid axle, shock absorbers, control arms, steering linkage, power steering system, steering column. Electrical Electronics: Battery, charging system, starting system, lighting system, instrument cluster, dashboard controls, wiring diagrams for all circuits, fuses, relays, power windows, locks, mirrors, audio system. Body Chassis: Frame construction, body panels, doors, hood, tailgate, bumpers, interior trim, seats, convertible top system, hardtop installation/removal. HVAC: Air conditioning system, heating system, ventilation, blower motor, controls. Fuel Emissions: Fuel tank, fuel pump, fuel lines, fuel injectors, evaporative emission control system (EVAP). Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement, brake pad and rotor replacement, tire rotation, battery maintenance. Diagnostics Troubleshooting: Systematic diagnostic procedures for all major vehicle systems, troubleshooting guides for common issues, diagnostic trouble codes (DTCs). Repair Rebuild: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for engines, transmissions, axles, suspension, brakes, and electrical components. Specifications Tolerances: Torque specifications for all fasteners, engine specifications (bore, stroke, compression ratio), bearing clearances, valve lash, wheel alignment specifications. Wiring Diagrams: Comprehensive, full-color wiring diagrams for all electrical systems, including engine control, lighting, body electronics, and comfort systems. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including advanced diagnostic procedures and detailed component specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick access to information. Print Quality Quality: High-resolution, clear diagrams and text for easy readability. Binding Type Type: N/A (Downloadable PDF) Paper Type Type: N/A (Downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine 1: 2.5L (150 cu in) AMC 150 Inline-4 Engine 2: 4.0L (242 cu in) AMC 242 Inline-6 Performance 4.0L Horsepower: 181 hp @ 4600 rpm (approx.) 4.0L Torque: 222 lb-ft @ 3200 rpm (approx.) 2.5L Horsepower: 117 hp @ 4500 rpm (approx.) 2.5L Torque: 135 lb-ft @ 3500 rpm (approx.) Fuel System Type: Multi-point fuel injection (MPI) Engine Management ECM: Chrysler's PCM (Powertrain Control Module) with diagnostic capabilities. 🔧 Transmission Standard Transmission 1: 5-speed Manual (AX-5 for 2.5L, NV3550 for 4.0L from 2000 onwards) Optional Transmission 2: 3-speed Automatic (30/42RH) for 2.5L, 4-speed Automatic (42RLE) for 4.0L from 2003 onwards Features Transfer Case: Command-Trac NV231J (standard), Rubicon's Rock-Trac NV241OR (optional) Fluid Specifications Manual Fluid: Mopar Manual Transmission Lubricant (or equivalent meeting API GL-3/GL-4, SAE 75W-90) Automatic Fluid: Mopar ATF+4 (or equivalent meeting Chrysler spec MS-9602) 📐 Dimensions Exterior Wheelbase: 93.4 inches Length: 151.3 inches Width: 66.5 inches Height: 70.5 inches (soft top) Weights Curb Weight Est: 3400 - 3800 lbs (depending on configuration) Towing Capacity: 2000 lbs Off Road Ground Clearance: 10.2 inches (approx.) Approach Angle: 43 degrees Departure Angle: 37 degrees Breakover Angle: 26 degrees 🛡️ Safety Features Ratings NHTSA Rollover: 3-star (typical for this era of SUVs) Active Features ABS: Available on most models, especially later years. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: 3-point front and rear seat belts. Construction Frame: Robust body-on-frame construction for durability and off-road resilience. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player (optional), cassette player (early models). Speaker configurations varied. Navigation: Not available from the factory during this period; aftermarket solutions are common. Driver Assistance Cruise Control: Available on most models. Connectivity Aux Input: Not standard; aftermarket solutions typically required for AUX/USB input. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendation). Transmission Fluid Interval: Automatic: 60,000-100,000 miles; Manual: Inspect periodically, change...