Jeep Grand Cherokee WJ/WG 2004 Service Manual

DaimlerChrysler factory service manual for the 2004 Jeep Grand Cherokee WJ and WG, covering LHD/RHD and 4x2/4x4 configurations. Mechanical engine repair covers the 4.0L and 4.7L gasoline engines, including High Output differences; selected 2.7L turbo-diesel systems are also addressed.

PDF Search, Bookmarks and Wiring Detail

Search and diagram access: Service text and connector tables support PDF text search, but many wiring-diagram labels are not searchable. Detailed chapter bookmarks are embedded; some top-level bookmarks point to separate files. Small circuit, connector and wire-color labels on the checked wiring pages are readable when enlarged.

One printable PDF contains 2,333 pages, including five opening cover/reference pages and the two closing service-comment and return-address pages.

Powertrain Overhaul, Chassis Service and Circuit Diagnosis

These selected workshop topics provide a preview of the contents. Further sections cover cruise-control diagnosis and wiper/washer service.

• Gasoline engine repair: Step-by-step engine removal and installation, cylinder-head and valve service, lubrication diagnosis, internal engine repair, inspection limits and assembly specifications.

• Transmissions and transfer cases: 42RE and 545RFE road testing, hydraulic and air-pressure checks, internal overhaul, plus NV147, NV242 and NV247 teardown, assembly, seal and shift-cable procedures.

• Axles and propeller shafts: Balance, runout and operating-angle diagnosis; CV and single/double Cardan joint service; axle-shaft, seal and differential repair.

• Suspension and steering: Hub/bearing and ball-joint replacement, control arms, springs, stabilizer and track bars, steering gear/pump/linkage service, bleeding and alignment data.

• Brakes and ABS: Base-brake and parking-brake service, hydraulic diagnosis, ABS/HCU removal and installation, wheel-speed sensors and scan-tool-assisted ABS bleeding.

• Electrical systems: Power distribution, junction block, grounds, PCI bus, starting/charging, fuel/ignition, transmission and body circuits, with wiring diagrams, connector pin-outs and location views.

• Body and HVAC: Doors, liftgate, seats, sunroof and body dimensions, plus A/C evacuation/charging, HVAC housing service and manual/Automatic Zone Control diagnosis.

This manual was prepared for professional automotive technicians involved in daily repair work; its diagnostic and overhaul procedures call for a DRB III scan tool and assembly-specific service equipment.

Engine, Cooling and Fuel-System Work

Compression and combustion-leakage tests support mechanical diagnosis before teardown. Internal repair extends through camshaft and timing-chain work, piston/ring inspection, crankshaft and bearing fitting, oil-pump service and manifold work.

Cooling coverage includes leak and combustion-gas checks, thermostat testing, water-pump service and system filling/bleeding. Gasoline fuel-delivery diagnosis and injector service are supported by fuel-system tests, while the emissions chapter explains evaporative leak detection and related component checks.

Diesel scope: The 2.7L/WG configuration appears in vehicle identification, lubricant/capacity data, diesel wiring and pin-outs, power-steering procedures, tire specifications and A/C component service. The dedicated mechanical engine repair chapters cover the gasoline engines; this volume does not provide a complete diesel engine overhaul chapter.

Transmission Diagnosis and Internal Repair

The 42RE Clutch and Band Application Chart connects slipping symptoms with the components applied in each range. Hydraulic and air tests then help narrow the probable cause before disassembly.

The overhaul sections cover clutches, pumps, planetary geartrains, torque converters and valve bodies, with 42RE band/servo work, end-play and clearance data, and component-specific tools. The 42RE and 545RFE hydraulic schematics and pressure-port illustrations support the diagnostic procedures.

TCM Quick Learn and Drive Learn procedures address adaptation after specified transmission repairs. NAG1 coverage is limited to fluid references; its inclusion in the specifications does not represent a complete overhaul section.

Axle Setup, Alignment and Service Tools

The 186FBI, 198RBI and 226RBA chapters include differential-carrier removal, pinion-depth shim selection, side-bearing preload, ring-gear backlash and tooth-contact-pattern interpretation. Trac-Lok and Vari-Lok operational tests accompany the rebuild procedures.

Wheel Alignment Measurements and separate standard/Up-Country tables distinguish caster, camber, toe and rear thrust-angle data. Pattern Interpretation charts show how gear-contact markings relate to axle setup.

Tool references include Inclinometer 7663, Suspension Bushing Remover/Installer 7932 and Ball Joint Tool Kit 6289. Differential work also calls out Dial Indicator C-3339, Pinion Depth Set 6774 and Axle Housing Spreader W-129-B with Adapter Kit 6987B.

Factory cautions explain how tightening rubber-bushed arms away from normal ride height can cause premature wear, while incorrect Vari-Lok oil-feed orientation can damage anti-rotation tabs. The axle chapters also warn that backing off the pinion nut cannot restore an over-crushed spacer and that reused ring-gear bolts can fracture, causing extensive damage.

Electrical Diagnosis, Body and HVAC Details

The 8W wiring section separates gasoline/diesel, LHD/RHD and export circuits. ABS, Sentry Key, airbags, HVAC, lighting, trailer tow, power windows, locks, mirrors and seats are covered alongside splice information and connector/ground/splice location illustrations.

Automatic Zone Control coverage includes fault-code, input-circuit and output/actuator tests. HVAC housing and component procedures accompany refrigerant service; faulty manual and AZC control panels are replaced as assemblies.

DRB III programming and system diagnosis are discussed, but many module-specific DTC pinpoint tests refer to separate diagnostic publications. Those publications are not included in this single-PDF download.

Component torque charts, fluid specifications, pressure-test data, electrical values, fit/wear limits, body gap/opening dimensions, and sealer/weld-location drawings support the procedures. Follow the factory warnings for vehicle and axle support, spring-loaded components, brake hydraulics, airbag disarming and refrigerant service.

A Preview of Axle Backlash and Transmission Clearances

For the 198RBI rear axle, the specification table gives ring-gear backlash of 0.12–0.20 mm. This accompanies the pinion-depth and tooth-contact-pattern adjustment material.

The 545RFE assembly specifications list output-shaft end play of 0.22–0.55 mm and input-shaft end play of 0.46–0.89 mm. These are separate inspection parameters within the transmission overhaul data.