Jeep Wrangler (TJ) 1996 thru 2006, repair e-manual

Content

Introduction

• Vehicle identification number
• Vehicle emission control information
• Vehicle certification label
• Body code plate
• International symbols
• Fastener identification
• Fastener usage
• Metric system
• Torque references

Lubrication and maintenance

• International symbols
• Parts and lubricant recommendation
• Fluid types
• Fluid capacities
• Maintenance schedules
• Hoisting
• Towing
• Jump starting
• Emergency tow hooks

Suspension

• Wheel alignment
• Front
• Rear

Differential and driveline

• Propeller shaft
• Front axle - 181FBI
• Front axle - 216FBI
• Rear axle - 194RBI
• Rear axle - 216RBI

Brakes

• Brakes - base
• Brakes - ABS

Clutch

• Clutch
• Clutch disc
• Clutch release bearing
• Flywheel
• Pilot bearing
• Linkage
• Master cylinder
• Clutch pedal
• Clutch pedal position switch

Cooling

• Cooling
• Accessory drive
• Engine
• Transmission

Audio / video

• Audio
• Amplified subwoofer
• Antenna body and cable
• Radio
• Radio noise suppression components
• Speaker

Chime / buzzer

• Chime warning system

Electronic control modules

• Communication
• Controller antilock brake
• Data link connector
• Powertrain control module
• Sentry key immobilizer module
• Transmission control module

Engine systems

• Battery system
• Charging
• Starting

Heated systems

• Heated glass
• Heated mirrors

Horn

• Horn system
• Horn
• Horn switch

Ignition control

• Ignition control
• Auto shut down relay
• Camshaft position sensor - 2.4l
• Camshaft position sensor - 4.0l
• Coil rail - 4.0l
• Ignition coil - 2.4l
• Spark plug
• Spark plug cable

Instrument cluster

• Instrument cluster
• Abs indicator
• Airbag indicator
• Brake/park brake indicator
• Check gauges indicator
• Cruise indicator
• Engine temperature gauge
• Fog lamp indicator
• Front lock indicator
• Fuel gauge
• High beam indicator
• Low fuel indicator
• Malfunction indicator lamp
• Odometer
• Oil pressure gauge
• Rear lock indicator
• Seatbelt indicator
• Shift indicator (transfer case)
• Skis indicator
• Speedometer
• Tachometer
• Turn signal indicator
• Upshift indicator
• Voltage gauge

Lamps

• Lamps / lighting - exterior
• Lamps / lighting - interior

Power system

• Automatic day / night mirror

Restraints

• Restraints
• Airbag control module
• Child restraint anchor
• Clockspring
• Driver airbag
• Front seat belt and retractor
• Front seat belt buckle
• Passenger airbag
• Passenger airbag door
• Passenger airbag on / off switch
• Rear seat belt and retractor
• Rear seat belt buckle
• Seat belt switch
• Seat belt turning loop adjuster

Speed control

• Speed control
• Cable
• Servo
• Switch
• Vacuum reservoir

Vehicle theft security

• Vehicle theft security
• Skis indicator
• Transponder key

Wipers / washers

• Front wipers / washers
• Rear wipers / washers

Wiring

• Wiring diagram information.
• Component index
• Power distribution
• Fuse block
• Ground distribution
• Bus communications
• Charging system
• Starting system
• Fuel / ignition system
• Transmission control system
• Vehicle speed control
• Antilock brakes
• Vehicle theft security system
• Instrument cluster
• Horn / cigar lighter / power outlet
• Air conditioning-heater
• Airbag system
• Interior lighting
• Audio system
• Rear window defogger
• Front lighting
• Rear lighting
• Turn signals
• Wipers
• Splice information
• Connector pin-outs
• Connector / ground / splice location
• Power distribution

Engine

• Air cleaner element
• Air cleaner housing
• Cylinder head
• Camshaft oil seal(s)
• Camshaft(s)
• Cylinder head cover
• Intake / exhaust valves and seats
• Valve springs
• Hydraulic lifters
• Rocker arms
• Engine block
• Connecting rod bearings
• Crankshaft
• Piston and connecting rod
• Piston rings
• Vibration damper
• Structural collar
• Engine mounting
• Front mount
• Rear mount
• Lubrication
• Oil
• Oil filter
• Oil pan
• Oil pressure sensor / switch
• Oil pump
• Intake manifold
• Exhaust manifold
• Timing belt cover
• Timing belt and sprocket
• Timing belt tensioner and pulley
• Balance shafts and carrier assembly
• Balance shaft carrier
• Balance shaft chain

Exhaust system

• Exhaust system
• Catalytic converter
• Exhaust pipe
• Heat shields
• Muffler
• Tailpipe

Frame and bumpers

• Frame and bumpers
• Front extension
• Front bumper
• Rear extension
• Rear bumper
• Frame
• Transfer case skid plate
• Fuel tank skid plate
• Front tow hook
• Rear tow hook
• Transmission skid plate

Fuel system

• Fuel delivery
• Fuel injection

Steering

• Steering
• Column
• Gear
• Linkage
• Pump

Transmission and transfer case

• Manual - NV1500
• Manual - NV3550
• Automatic transmission - 42RLE
• Transfer case - NV231
• Transfer case - NV241

Tires / wheels

• Tires / wheels
• Tires
• Spare tire
• Spare tire carrier
• Wheels
• Studs

Body

• Body
• Tailgate
• Full door
• Half door
• Exterior
• Hood
• Instrument panel
• Interior
• Paint
• Removeable top
• Seats
• Stationary glass
• Weatherstrip / seals
• Body structure

Heating and air conditioning

• Heating and air conditioning
• Controls
• Distribution
• Plumbing

Emissions control

• Emissions control
• Evaporative emissions

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