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Introduction

0Lubrication & Maintenance

0a Maintenance Schedules

2Suspension

3Differential & Driveline

5Brakes

6Clutch

7Cooling

8A Audio

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

9Engine

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 SAFETY CERTIFICATION LABEL

DESCRIPTION ..........................1

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION ..........................1

VEHICLE EMISSION CONTROL INFORMATION

(VECI) LABEL

DESCRIPTION ..........................2

BODY CODE PLATE

DESCRIPTION

BODY CODE PLATE ....................3

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................4

FASTENER IDENTIFICATION

DESCRIPTION ..........................5

FASTENER USAGE

DESCRIPTION

DESCRIPTION - FASTENER USAGE ........8

DESCRIPTION - THREADED HOLE REPAIR . . 8

METRIC SYSTEM

DESCRIPTION ..........................8

TORQUE REFERENCES

DESCRIPTION .........................10

VEHICLE SAFETY

CERTIFICATION LABEL

DESCRIPTION

A vehicle safety certification label (Fig. 1) is

attached to every DaimlerChrysler Corporation vehi-

cle. The label certifies that the vehicle conforms to all

applicable Federal Motor Vehicle Safety 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.

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 decod-

ing 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.

Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL -

TYPICAL

TJ INTRODUCTION 1

VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = United States

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

7 Body Style 9 = Open Body

8 Engine P = 2.4L Gasoline

S = 4.0L Gasoline

9 Check Digit 0 through 9 or X

10 Model Year 3=2003

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.

2). It cannot be removed without defacing informa-

tion and destroying the label.

The label contains the vehicle’s emission specifica-

tions 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 sche-

matic. These labels are permanently attached and

cannot be removed without defacing information and

destroying label.

Fig. 2 VECI Label Location

1 - VECI LABEL

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.

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

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

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.

INTERNATIONAL SYMBOLS

DESCRIPTION

The graphic symbols illustrated in the following

International Control and Display Symbols Chart

(Fig. 5) are used to identify various instrument con-

trols. The symbols correspond to the controls and dis-

plays that are located on the instrument panel.

Fig. 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer

2 Fog Lamps 14 Fuel

3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature

4 Turn Warning 16 Battery Charging Condition

5 Hazard Warning 17 Engine Oil

6 Windshield Washer 18 Seat Belt

7 Windshield Wiper 19 Brake Failure

8 Windshield Wiper and Washer 20 Parking Brake

9 Windscreen Demisting and Defrosting 21 Front Hood

10 Ventilating Fan 22 Rear hood (Decklid)

11 Rear Window Defogger 23 Horn

12 Rear Window Wiper 24 Lighter

4 INTRODUCTION TJ

BODY CODE PLATE (Continued)

FASTENER IDENTIFICATION

DESCRIPTION

The SAE bolt strength grades range from grade 2

to grade 8. The higher the grade number, the greater

the bolt strength. Identification is determined by the

line marks on the top of each bolt head. The actual

bolt strength grade corresponds to the number of line

marks plus 2. The most commonly used metric bolt

strength classes are 9.8 and 10.9. The metric

strength class identification number is imprinted on

the head of the bolt. The higher the class number,

the greater the bolt strength. Some metric nuts are

imprinted with a single-digit strength class on the

nut face. Refer to the Fastener Identification and

Fastener Strength Charts (Fig. 6) and (Fig. 7).

TJ INTRODUCTION 5

Fig. 6 FASTENER IDENTIFICATION

6 INTRODUCTION TJ

FASTENER IDENTIFICATION (Continued)

Fig. 7 FASTENER STRENGTH

TJ INTRODUCTION 7

FASTENER IDENTIFICATION (Continued)

FASTENER USAGE

DESCRIPTION

DESCRIPTION - FASTENER USAGE

WARNING: USE OF AN INCORRECT FASTENER

MAY RESULT IN COMPONENT DAMAGE OR PER-

SONAL INJURY.

Fasteners and torque specifications references in

this Service Manual are identified in metric and SAE

format.

During any maintenance or repair procedures, it is

important to salvage all fasteners (nuts, bolts, etc.)

for reassembly. If the fastener is not salvageable, a

fastener of equivalent specification must be used.

DESCRIPTION - THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using

a Helicoilt. Follow the vehicle or Helicoiltrecommen-

dations for application and repair procedures.

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one,

ten, one hundred, one thousand and one million.

The following chart will assist in converting metric

units to equivalent English and SAE units, or vise

versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters

(N·m) N·m x 8.851 = in-lbs

ft-lbs x 1.3558 = Newton Meters

(N·m) N·m x 0.7376 = ft-lbs

Inches Hg

(60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi

Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches

Feet x 0.3048 = Meters (M) M x 3.281 = Feet

Yards x 0.9144 = Meters M x 1.0936 = Yards

mph x 1.6093 = Kilometers/Hr.

(Km/h) Km/h x 0.6214 = mph

Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec

mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph

Kilometers/

Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).

Also, use the chart to convert between millimeters

(mm) and inches (in.) (Fig. 8).

8 INTRODUCTION TJ

Fig. 8 METRIC CONVERSION CHART

TJ INTRODUCTION 9

METRIC SYSTEM (Continued)

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