🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Codes Platform Code: TJ 👋 Introduction Market Position Market Position: The 2004 Jeep Wrangler TJ represents a highly capable and iconic off-road vehicle, known for its ruggedness and go-anywhere attitude. This service manual positions itself as an essential tool for owners and independent mechanics seeking to maintain and repair this specialized vehicle. Competitive Analysis Competitive Analysis: While direct competitors in the off-road SUV segment existed, the Wrangler's unique open-air design, solid axles (on earlier models like the TJ), and distinct styling set it apart. This manual caters to a niche but dedicated enthusiast base. Key Features Key Features: Focus on off-road capability, robust construction, iconic design, and a strong aftermarket support community. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Fuel System, Cooling System, Exhaust System, Body & Chassis, Interior Trim, Diagnostics Page Count Estimated Page Count: Approximately 1000+ Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component specifications, timing, valve adjustments, cooling system, lubrication system. Fuel And Emissions: Fuel injection system diagnostics, fuel pump, injectors, EVAP system, emissions controls. Transmission Drivetrain: Manual and automatic transmission overhaul, transfer case service, axle inspection and repair, driveshaft, U-joints. Suspension Steering: Front and rear suspension components, alignment specifications, steering gear, power steering system. Brakes: Front and rear brake systems (disc/drum), ABS diagnostics, hydraulic system, parking brake. Electrical System: Battery, charging system, starting system, ignition system, lighting, fuses, relays, wiring diagrams, diagnostic trouble codes (DTCs). HVAC: Air conditioning system, heating system, blower motor, climate control diagnostics. Body Chassis: Body panel removal/installation, interior trim, exterior trim, doors, hood, tailgate, frame components. Procedures Included Maintenance: Regular scheduled maintenance, fluid checks and changes, filter replacements, lubrication points. Diagnostics: Troubleshooting guides for common problems, diagnostic trouble code (DTC) interpretation, symptom-based diagnostics. Repair: Step-by-step repair instructions for all major vehicle systems, including component removal, overhaul, and reinstallation. Wiring Diagrams: Detailed electrical system wiring diagrams for various circuits and components. Technical Depth Technical Depth: Comprehensive, covering everything from basic maintenance tasks to full engine and transmission rebuilds, including advanced diagnostic procedures. 📊 Manual Specifications File Format File Format Details: PDF format, likely optimized for searchability and printing. May include hyperlinked table of contents. Print Quality Print Quality: High resolution, suitable for clear printing of diagrams and text. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4.0L Straight-6 (High Output) Engine Displacement: 3952 cc (241 cubic inches) Engine Configuration: Inline 6-cylinder, Overhead Valve (OHV) Performance Horsepower: 190 hp @ 4,400 rpm Torque: 235 lb-ft @ 3,200 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Engine Features Block Material: Cast Iron Cylinder Head Material: Cast Iron Bore X Stroke: 3.88 in x 3.41 in (98.5 mm x 86.7 mm) Compression Ratio: 8.7:1 🔧 Transmission Standard Transmission Type: NV3550 5-Speed Manual Transmission Optional Transmission Type: 42RLE 4-Speed Automatic Transmission Features Transfer Case: NV241OR 'Rock-Trac' (Rubicon models) or NV231 'Command-Trac' (Sport, Sahara models) Gear Ratios Manual: 3.75:1 (1st), 2.17:1 (2nd), 1.36:1 (3rd), 1.00:1 (4th), 0.78:1 (5th), 3.42:1 (Reverse) Gear Ratios Automatic: 2.80:1 (1st), 1.53:1 (2nd), 1.00:1 (3rd), 0.71:1 (4th) Fluid Specifications Manual Transmission Fluid: MS-9224 Chrysler Specification (e.g., Mopar Manual Transmission Lubricant, synthetic) Automatic Transmission Fluid: MS-9602 Chrysler Specification (ATF+4) Transfer Case Fluid: MS-9224 Chrysler Specification (e.g., Mopar Manual Transmission Lubricant, synthetic) 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 158.8 inches (4034 mm) Width: 66.5 inches (1689 mm) Height: 70.5 inches (1791 mm) Ground Clearance: Approx. 8.7 inches (221 mm) with standard tires Weights Curb Weight: Approximately 3,500 - 3,800 lbs (1588 - 1724 kg) depending on configuration 🛡️ Safety Features Ratings NHTSA Frontal Crash Test: Driver: 4 Stars, Passenger: 4 Stars (2004 Model Year) NHTSA Side Impact Crash Test: Front Driver: 5 Stars, Front Passenger: 5 Stars (2004 Model Year) Active Features Active Features: Four-wheel Anti-lock Brakes (ABS) Passive Features Passive Features: Driver and front passenger airbags, seatbelt pretensioners. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM stereo with CD player. Optional Infinity speaker system available. Driver Assistance Driver Assistance Features: Limited; primarily focused on core driving dynamics. ABS is the main active safety feature. Connectivity Connectivity Features: No integrated Bluetooth or USB ports as standard. Aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first, using synthetic oil. Refer to manual for specific conditions. Tire Rotation Interval: Every 5,000 to 7,500 miles (8,000 to 12,000 km) Transmission Fluid Change: Every 30,000 to 60,000 miles (48,000 to 96,000 km), depending on usage (e.g., heavy towing, off-roading)....