🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2004 Chassis Code: TJ Codes Engine Code Primary: 4.0L Inline-6 (MPI) 👋 Introduction Market Position Vehicle Segment: Compact Sport Utility Vehicle (SUV), known for off-road capability and open-air driving experience. Target Audience: Enthusiasts, off-roaders, recreational users, and those seeking a robust, utilitarian vehicle. Competitive Analysis Competitors 2004: Toyota Tacoma (off-road focused), Suzuki Vitara, Nissan Xterra, Ford Bronco (earlier models), Land Rover Defender (global). Key Features Design Philosophy: Body-on-frame construction, solid front and rear axles, removable doors and roof (soft top or hard top options). Off Road Capability: Part-time 4WD system with low-range gearing, high ground clearance, excellent approach/departure angles. Powertrain Options: Renowned 4.0L 'PowerTech' inline-six engine, offering strong torque for off-road and towing. 📋 Manual Details Coverage Areas Coverage Focus: Factory Service and Repair Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: WinRAR (Digital Archive) / PDF 📖 Manual Coverage Systems Covered Engine: 4.0L PowerTech Inline-6 (MPI), diagnostic procedures, internal components, lubrication, cooling system, fuel system, ignition system, exhaust system, emissions control. Transmission: NV3550 5-Speed Manual Transmission; 42RLE 4-Speed Automatic Transmission: overhaul, diagnostics, clutch, torque converter, shift controls, fluid specifications. Drivetrain: Dana 30 (Front Axle), Dana 35c (Rear Axle) or optional Dana 44 (Rear Axle) differentials, transfer case (NV241 GII/241 DHD), driveshafts, U-joints, axle shafts, lubrication, bearing adjustment. Suspension: Front Solid Live Axle (Dana 30), Rear Solid Live Axle (Dana 35c/44), coil springs, shock absorbers, track bars, sway bars, control arms, bushing replacement, alignment specifications. Steering: Power steering system, steering gearbox, tie rod ends, steering column, alignment specifications, troubleshooting. Brakes: Front vented disc brakes, rear disc or drum brakes (depending on axle), ABS (if equipped), hydraulic system, brake fluid specifications, caliper and cylinder overhaul, bleeding procedures, parking brake. Electrical System: 12-volt negative ground system, battery, alternator, starter motor, wiring diagrams for all circuits, lighting, fuses, relays, ignition switch, power distribution, comfort systems. Body And Chassis: Body construction, frame integrity, doors, hood, tailgate, windshield, body panels, interior trim, convertible top mechanisms, rust repair, paint and finish. HVAC: Heating, ventilation, and air conditioning (HVAC) system: refrigerant charge, compressor, evaporator, condenser, blower motor, control panel, leak detection. Restraint Systems: Seat belts, airbags (if equipped): diagnostic procedures, SRS module, component replacement. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, tire rotation, lubrication points, spark plug replacement. Diagnostics: Troubleshooting guides for common and complex issues, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, use of scan tools. Repair: Step-by-step repair procedures for all major vehicle systems, component removal and installation, rebuilding procedures for engines, transmissions, and axles. Overhaul: Detailed overhaul procedures for major components such as the 4.0L engine, manual and automatic transmissions, and front/rear axles. Electrical Diagnostics: Use of wiring diagrams, multimeter usage, continuity testing, voltage drop testing, troubleshooting electrical faults. Body Repair: Panel replacement, dent repair, welding procedures, glass replacement, convertible top repair and adjustment. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostics and specifications. Detail Level: Detailed exploded views, torque specifications for all fasteners, clearances and adjustments, diagnostic flowcharts. Accuracy: Factory authorized procedures and specifications, ensuring accuracy for professional repair and enthusiast use. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) within a WinRAR archive. Searchable: Yes, text within PDFs is typically searchable. Printable: Yes, PDFs are generally printable. Print Quality Quality Descriptor: Digital scan quality, generally high resolution suitable for screen viewing and printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Name: 4.0L PowerTech Inline-6 Displacement: 3952 cc (241 cu in) Bore X Stroke: 98.4 mm x 86.7 mm (3.875 in x 3.414 in) Compression Ratio: 8.8:1 Valvetrain: Overhead Valve (OHV), 12 valves (2 per cylinder) Block Material: Cast Iron Head Material: Cast Iron Performance Horsepower Est: 190 hp @ 4600 rpm Torque Est: 235 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Regular Octane 87 (minimum) Fluid Capacities Engine Oil Capacity: 5 quarts (4.7 liters) with filter change, SAE 10W-30 or 10W-40 (refer to manual for temperature-specific recommendations) 🔧 Transmission Standard Type: NV3550 5-Speed Manual Optional Type: 42RLE 4-Speed Automatic Features Transfer Case: NV241 GII (Command-Trac 2-speed part-time 4WD system) Manual Fluid: NV3550: Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4 rated fluid, 2.5 pints) Automatic Fluid: 42RLE: ATF+4 (MS-9602), 5.5 quarts (5.2 liters) refill 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 158.8 inches (4033 mm) Width: 66.5 inches (1689 mm) Height: 71.9 inches (1826 mm) Ground Clearance: Approx. 8.5 inches (216 mm) Approach Angle: Approx. 43.6 degrees Departure Angle: Approx. 37.4 degrees Breakover Angle: Approx. 25.1 degrees Weights Curb Weight Est: 3750 - 4100 lbs (1700 - 1860 kg),...