Chrysler Vehicle User manual

GROUP TAB LOCATOR
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)