🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Chassis Code: TJ Codes Trim Levels Covered: All 2004 Wrangler TJ trims (e.g., SE, X, Sport, Sahara, Rubicon) 👋 Introduction Market Position Purpose: A comprehensive resource for Jeep Wrangler TJ owners and independent workshops to perform repairs and maintenance. Competitive Analysis Value Proposition: Provides dealership-level technical information at a fraction of the cost, empowering DIY repairs and saving money. Key Features Content Focus: Focuses on practical, step-by-step guidance with clear illustrations for ease of understanding, suitable for all skill levels. 📋 Manual Details Coverage Areas 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. Page Count Estimated Page Count: Likely 1000+ pages based on typical workshop manual density. Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth Depth: Extremely detailed, covering basic to advanced repair and overhaul procedures, including engine rebuilding. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy information retrieval. Print Quality Printability: All pages are printable, allowing users to create custom paper copies for workshop use. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 4.0L Power Tech Inline 6-Cylinder (I6) Engine Code: Typically referred to as the '4.0L' or 'AMC 242' Performance Horsepower Approx: 190 hp @ 4,600 rpm Torque Approx: 235 lb-ft @ 3,200 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Maintenance Items 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. 🔧 Transmission Standard Manual Transmission: New Venture Gear NV3550 5-speed manual transmission. Optional Automatic Transmission: Optional 42RLE 4-speed automatic transmission. Features 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. 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 160.0 inches (4064 mm) Width: 66.5 inches (1689 mm) Height: 71.5 inches (1816 mm) (soft top) Weights Curb Weight Approx: 3,500 - 4,000 lbs (1588 - 1814 kg), varies by trim and options. 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star rating (typical for SUVs of this era). Active Features ABS: Optional Anti-lock Braking System (ABS) available on certain trims. Passive Features Airbags: Driver and passenger front airbags. 💡 Technology Features Infotainment Audio Options: Factory AM/FM/CD players, optional Infinity sound system. Driver Assistance ABS: Optional ABS for enhanced braking control. Connectivity Connectivity Features: Basic connectivity, focusing on audio systems; advanced connectivity features are minimal for this era. 🔧 Maintenance Service Intervals 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. Fluid Specifications 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. Known Issues Common Problems: Potential for rear main seal leaks, exhaust manifold cracks, heater core leaks, and frame rust (depending on climate). Common...