2004 Jeep Wrangler TJ OEM Service & Repair Manual

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DaimlerChrysler Corporation UNITED STATES and CANADA The special service tools referred to herein are required for certain service operations. These special service tools or their equivalent, if not obtainable through a local source, are available through the following outlet. 28635 Mound Road, Warren, Michigan 48092, U.S.A. MILLER SPECIAL TOOLS SPX Corporation Telephone 1-800-801-5420 FAX 1-800-578-7375 INTERNATIONAL The special service tools referred to herein are required for certain service operations. These special service tools or their equivalent, if not obtainable through a local source, are available through the following outlet. 28635 Mound Road, Warren, Michigan 48092, U.S.A. MILLER SPECIAL TOOLS SPX Corporation Telephone 1-507-455-7320 FAX 1-800-578-7375 NEXT PAGE '

FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain description, operation, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo- nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide DaimlerChrysler Corporation with your comments and suggestions. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation. NEXT PAGE '

GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio/Video 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power System 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission and Transfer Case 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Component and System Index Service Manual Comment Forms (Rear of Manual)

INTRODUCTION TABLE OF CONTENTS page page VEHICLE IDENTIFICATION NUMBER DESCRIPTION .......................... 1 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL DESCRIPTION .......................... 2 VEHICLE CERTIFICATION LABEL DESCRIPTION .......................... 2 BODY CODE PLATE DESCRIPTION BODY CODE PLATE .................... 3 INTERNATIONAL SYMBOLS DESCRIPTION .......................... 5 FASTENER IDENTIFICATION DESCRIPTION .......................... 6 FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE ........ 9 DESCRIPTION - THREADED HOLE REPAIR ..9 METRIC SYSTEM DESCRIPTION ......................... 10 TORQUE REFERENCES DESCRIPTION ......................... 12 VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left A-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle. The Vehicle Identification Number is also imprinted on the: • Vehicle Safety Certification Label. • Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden- tification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta- tion. The formula to use the check digit is not released to the general public. VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation 2 Make J = Jeep 3 Vehicle Type 4 = MPV 4 Gross Vehicle Weight Rating E = 3001-4000 lbs. F = 4001-5000 lbs. 5 Vehicle Line A = Wrangler 4X4 (LHD) 4 = Wrangler 4X4 (RHD) 6 Series 2 = SE 3=X 4 = Sport 5 = Sahara 6 = Rubicon 7 Body Style 9 = Open Body 8 Engine 1 = 2.4L 4 cyl DOHC Gasoline S = 4.0L 6 cyl Gasoline TJ INTRODUCTION 1

POSITION INTERPRETATION CODE = DESCRIPTION 9 Check Digit 0 through 9 or X 10 Model Year 4=2004 11 Assembly Plant P = Toledo #2 12 thru 17 Vehicle Build Sequence VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. DaimlerChrysler permanently attaches the label in the engine compartment (Fig. 1). It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label. The VECI label contains the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Engine timing specifications (if adjustable) • Idle speeds (if adjustable) • Spark plug and gap The label also contains an engine vacuum schematic. These labels are permanently attached and cannot be removed without defacing information and destroying label. VEHICLE CERTIFICATION LABEL DESCRIPTION A vehicle certification label (Fig. 2) is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin. The label is located on the driver-side door shut- face. Fig. 1 VECI Label Location 1 - VECI LABEL Fig. 2 VEHICLE CERTIFICATION LABEL - TYPICAL 2 INTRODUCTION TJ VEHICLE IDENTIFICATION NUMBER (Continued)

BODY CODE PLATE DESCRIPTION BODY CODE PLATE A metal body code plate is attached to the floor pan under the drivers seat (Fig. 3). Disengage the snaps attaching the carpet to the floor pan to read the information. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate (Fig. 4). The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued). When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap. Fig. 3 Body Code Plate Location 1 - SNAP 2 - REAR CARPET 3 - BODY CODE PLATE 4 - SNAP 5 - FLOOR PAN 6 - FRONT CARPET Fig. 4 Body Code Plate Decoding 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - ROOF 4 - CAR LINE SHELL 5 - ENGINE 6 - TRIM 7 - VIN 8 - MARKET 9 - TRANSMISSION 10 - PAINT PROCEDURE 11 - VEHICLE ORDER NUMBER TJ INTRODUCTION 3

BODY CODE PLATE—LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13, 14, AND 15 Roof • VJN = Soft Top White • VJU = Soft Top Spice • VJX = Soft Top Black • VKN = Hard Top White • VKU = Hard Top Spice • VKX = Hard Top Black DIGITS 16, 17, AND 18 Car Line Shell • TJJ = Wrangler (LHD) • TJU = Wrangler (RHD) DIGIT 19 Price Class • L = Wrangler (All) DIGITS 20 AND 21 Body Type • 77 = Wheel Base (93.4 in.) BODY CODE PLATE—LINE 2 DIGITS 1,2, AND 3 Paint Procedure DIGIT 4 Open Space DIGITS 5 THROUGH 8 Primary Paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS) for color codes. DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • ED1 = 2.4L 4 cyl. MPI Gasoline • ERH = 4.0L 6 cyl. MPI Gasoline BODY CODE PLATE—LINE 1 DIGITS 1, 2, AND 3 Transmission Codes • DDD = NV3550 5 - speed Manual • DDK = AX15 5 - speed Manual • DG6 = 42RLE 4 - speed Automatic DIGIT 4 Open Space DIGIT 5 Market Code • B = International DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) (Refer to VEHICLE DATA/VEHICLE INFORMA- TION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for breakdown of VIN code. 4 INTRODUCTION TJ BODY CODE PLATE (Continued)

2004 Jeep Wrangler TJ OEM Service & Repair Manual

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