🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Model Years Covered: 1997-2006 Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact Sport Utility Vehicle (SUV) / Off-Road Vehicle Target Audience: Enthusiasts, off-roaders, DIY mechanics, owners seeking in-depth knowledge Competitive Analysis Competitors: Toyota 4Runner, Land Rover Defender, Suzuki Samurai, Ford Bronco (earlier generations) Key Features Iconic Design: Classic Jeep styling, removable doors and top, exposed hinges, upright grille Off Road Capability: Solid front axle, robust transfer case (Command-Trac or optional NV241OR Rock-Trac), short overhangs, excellent approach/departure angles Durability: Known for its rugged construction and ability to withstand demanding conditions 📋 Manual Details Coverage Areas Systems: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Bodywork, Interior Components, Fuel System, Exhaust System, Cooling System, Lubrication System, Emissions Control, Diagnostic Procedures, Troubleshooting Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual / Workshop Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full rebuild procedures, component identification, torque specifications, timing procedures, internal component diagnostics Engine Performance: Fuel delivery, ignition system, emission controls, sensor testing and replacement, performance tuning diagnostics Transmission Drivetrain: Manual and automatic transmission overhaul, transfer case service, axle inspection and repair, driveline maintenance Suspension Steering: Coil spring suspension, shock absorber replacement, steering linkage, power steering system repair, alignment procedures Brakes: Front disc brakes, rear drum or disc brakes (depending on model year/trim), ABS system diagnostics, brake fluid service Electrical System: Wiring diagrams for all circuits, component testing, starter, alternator, battery, lighting systems, power windows/locks HVAC: Air conditioning system service, heater core replacement, blower motor diagnostics, climate control operation Bodywork Interior: Door panel removal, seat adjustment, interior trim, convertible top maintenance, body panel alignment, rust repair guidelines Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement Diagnostics: Troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs), component testing procedures Repair: Step-by-step repair instructions for all major components and systems, including complex rebuilds Installation: Instructions for replacing components, installing accessories, and performing upgrades Technical Depth Depth: Comprehensive: Covers from basic maintenance to full engine and transmission rebuilds, including detailed electrical troubleshooting and component-level diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval Printable: Printable pages for on-the-job reference Print Quality Image Resolution: High-resolution diagrams and images ensuring clarity Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4.0L Inline-6 (OHV) - PowerTech Displacement: 3956 cc (241.4 cubic inches) Bore X Stroke: 98.4 mm x 86.6 mm (3.87 in x 3.41 in) Compression Ratio: 8.8:1 Horsepower: 181 hp @ 4600 rpm (approx.) Torque: 220 lb-ft @ 3200 rpm (approx.) Engine Variants Optional Engine 2.5L I4: 2.5L (150 ci) Inline-4 (IDLE/VIN 4) Optional Engine 4.7L V8: Note: While the 4.7L V8 was an option for some Grand Cherokees in this era, it was NOT factory-fitted to the TJ Wrangler. Manual coverage would reflect only I4 and I6. Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Fuel Tank Capacity: 19 gallons (72 Liters) 🔧 Transmission Standard Transmission Type: 5-Speed Manual (AX-5 or NV3550) Optional Transmission Type: 4-Speed Automatic (42RLE) Features Transfer Case: NV131 Command-Trac (2-speed, part-time 4WD) standard; NV241OR Rock-Trac (2-speed, part-time 4WD with lower crawl ratio) optional on Rubicon Fluid Specifications Manual Transmission Fluid: Mopar Manual Transmission Lubricant (or equivalent GL-3/GL-4, SAE 75W-90) - Check manual for specific part numbers and viscosity Automatic Transmission Fluid: ATF+4 (MS-9602) Transfer Case Fluid: Mopar NV241 Transfer Case Lubricant (or equivalent ATF+4) 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Overall Length: 151.3 inches (3843 mm) Overall Width: 66.5 inches (1689 mm) Overall Height: 73.7 inches (1872 mm) (with hardtop) Interior Passenger Volume: 82.0 cu. ft. (2.32 m³) Cargo Cargo Volume Behind Rear Seat: 35.9 cu. ft. (1.02 m³) Cargo Volume Max: 71.2 cu. ft. (2.01 m³) Weights Curb Weight: Approx. 3,400 - 3,700 lbs (1542 - 1678 kg) depending on configuration Gross Vehicle Weight Rating Gvwr: Approx. 4,950 lbs (2245 kg) 🛡️ Safety Features Ratings NHTSA Frontal Impact: Not extensively rated for this era; however, known for robust body-on-frame construction. IIHS Side Impact: Not rated. Active Features ABS: Standard on most models, optional on early models. (Check specific model year) Passive Features Airbags: Driver and passenger airbags standard Seatbelts: 3-point front seatbelts, lap belts in rear Roll Cage: Integral roll cage and sport bar for enhanced occupant protection 💡 Technology Features Infotainment Audio System: Optional AM/FM stereo with CD player, 6-speaker system Navigation: Not available from factory Driver Assistance Cruise Control: Optional Connectivity Connectivity Features: Limited to optional power windows and locks on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-6,000 miles (5,000-10,000 km) or 6-12 months, depending on...