Jeep Wrangler 1997 User manual

CHRYSLER
CORPORATION
SERVICE
MANUAL
1997
JEEP®
WRANGLER
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover .
D
COR RP PORATION
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OFCHRYSLER CORPORATION .
Chrysler Corporation reserves
the right to make changes in design or to
make additions to or
improvements in its products without imposing any obli-
gations upon itself to install them on
its products previously manufactured .
Litho in U .S .A . Copyright © 1996 Chrysler Corporation 10MO196
Paper Content
50% Recycled

FOREWORD
The information contained in this
service manual has beenprepared for the
professional automotive tech-
nician involved in daily repair
operations . This manual does not cover theory of
operation, which is addressed
in service training material . 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 general
information, 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 Tat)
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
infor-
mation 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 Chrysler
Corporation withyour
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 torquevalues 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 .
Chrysler
Corporation reserves the right to change testing
procedures, specifications, diagnosis, repair
methods, or vehicle wiring
at any timewithout prior notice or
incurring obligation .

GROUP TAB LOCATOR
Service Manual Comment Forms

(Rear of Manual)

TJ
INTRODUCTION
CONTENTS
GENERAL INFORMATIONI I
VEHICLE
IDENTIFICATION NUMB R
The Vehicle Identification Nu her (VIN) plate is
located on the lower windshield ence 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 :
" Body Code Plate .
" Vehicle Safety Certification Label .
" Frame rail .
VEHICLE ~IDENTIFICATION NUMBER DECODING
CHART
INTRODUCTION 1
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 .
POSITION INTERPRETATION
CODE = DESCRIPTION
1
re
ountry 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
Y = Wrangler 4X4
6
Series 1 = Sport
2=SE
4 = Sahara
7 Body Style
9 = Open Body
8Engine
j
H = 2 .5L Leaded-Gasoline
P = 2 .5L Unleaded-Gasoline
S = 4 .OL Unleaded-Gasoline
V = 4 .OL
Leaded-Gasoline
9 Check Digit
10
Model Year V = 1997
11
ssembly Plant P = Toledo #2
12 thru 17 Vehicle Bu
i
ld Seq
u
ence
page page
GENERAL INFORMATION METRIC
SYSTEM .... .............. . . .... 7
BODY CODE PLATE
.........
I ........ ..... 2
TORQUE REFERENCES . ............. . . .... 7
FASTENER IDENTIFICATION .......... .
.....
4 VEHICLE
DIMENSIONS . .............. . .... 3
FASTENER USAGE ............... . . . .....
7 VEHICLE IDENTIFICATION NUMBER .... . . ... 1
INTERNATIONAL
VEHICLE
CON ROL AND
VEHICLE SAFETY CERTIFICATION
LABEL
. ....
2
DISPLAY SYMBOLS ....... ....... .....
4

2 INTRODUCTION

TJ
GENERAL INFORMATION (Continued)
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety
certification label (Fig . 1) is
attached to
every Chrysler Corporation vehicle . The
label certifies that the vehicle
conforms to all appli-
cable Federal Motor Vehicle Safety Standards .
The
label also lists :
" Paint and Trim codes .

Fig . 2 Body Code Plate Location
" Country
of origin .
The label is located on the driver-side door shut-

PRIMARY

SECONDARY

VINYL ROOF
PAINT
PAINT
face .
MFD BY

CHRYSLER

DATE
OF
MFR

GUUR
CORPORATION

1X_XX

06400 LB 2903 KG
GAUR FRONT

uITH TIRES

RIMS AT

PSI COLD

VEHICLE

F

CAR
3300 LB 1497 KG

P235/75R15X1_

15 X 6 .5HD

35

ORDER
GAUp REAR

uITH 11RES

RIMS AT

PSI COLD

NUMBER

LINE
7
SHELL
3850 LB 1747 KG

P235/75R15XL

15 X 6 .5HD

41

PAINT

(3)
XXXX :XXXX K XXX XXXXXX

ENGINE
THIS VEHICLE CONFORMS 10 ALL APPLICABLE FEDERAL MOTOR VEHICLE
SAFETY

PROCEDURE

(2) xxX XXXX XXXX XXXX XXX
STANDARDS
IN EFFECT ON
THE
DAZE OF MANUFACTURE SHOUN ABOVE,

(1)

XxX X

XXXXXXXXXXXXXXXXX

TRIM
VIN : XXXXXXXXXXXXXXXXX

TYPE :

TRUCK

SINGLE X

DUAL
BODY CODE PLATE
e020cdss
Fig . 1 Vehicle Safety
Certification Label-Typical
OO
FLOOR
PAN
SNAP
BODY
CODE
PLATE
SNAP
FWD
TRANSMISSION
VIN
MARKET
Fig .
3
Body Code Plate Decoding
BODY CODE
PLATE-LINE 3
DIGITS
1 THROUGH 12
LOCATION
AND DECODING

Vehicle Order Number
A metal body code plate
is attached to the floor pan
under the drivers
seat (Fig . 2) . Disengage the snaps

DIGITS 13, 14, AND 15
attaching the carpet to the floor pan to read the

Open
Space
information . There are seven lines of information on
the body code
plate . Lines 4, 5, 6, and 7 are not used

DIGITS 16, 17,
AND 18
to
define service information . Information reads from

Car Line Shell
left to right, starting with line 3 in the
center of the

"
TJJ = Wrangler
(LHD)
plate to line 1 at the bottom of
the

_plate (Fig . 3) .

"
TJU -
Wrangler (AHD)
The last code imprinted on a vehicle
code plate will
be followed by the imprinted
word END . When two

DIGIT 19
vehicle code
plates are required,, the last available

Price Class
spaces on the first plate
will be imprinted with the

"
L = Wrangler (All)
letters CTD (for continued) .
When a second vehicle code
plate is necessary, the

DIGITS 20 AND 21
first four spaces on' each row
will
Inot
be used because

Body Type
of the plate overlap .

"
77 = Wheel
Base (93 .4 in .)
931N-S
" 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) .
w .
" Type of vehicle .
.16
"
Type of rear wheels
.
FRONT
" Bar code . CARPET
" Month, Day and Hour
(MDH) of final assembly .

TJ
GENERAL
INFORMATION (0ontinued)
i
BODY CODE PLATE-LINE 2
DIGITS 1,2, AND 3
Paint Procedure
DIGIT 4
Open
Space
DIGITS 5
THROUGH 8
Primary Paint
Refer to
Group 23, Body 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
" EPE = 2 .5 L 4 cyl . MPI Gasoline
" ERH = 4.OL 6 cyl . MPI Gaso4ne
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transmission Codes
" DDQ = AX5 5-speed Manual
" DDO =
AX15 5-speed Manual
" DGD = 30RH
3-speed Automatic
DIGIT 4
Open
Space
DIGIT 5
Market Code
" B = International
" C =
Canada
" M = Mexico
" U = United States
DIGIT 6
Open Space
VEHICLE EXTERIOR
DIMENSIONS
VEHICLE INTERIOR DIMENSIONS
INTRODUCTION 3
" DGG = 32RH 3-speed Automatic
DIGITS 7 THROUGH 23
Vehicle Identification Number
(VIN)
Refer to Vehicle Identification Number
(VIN) para-
graph for proper breakdown of
VIN code .
VEHICLE DIMENSIONS
The vehicle dimension data charts list the exterior
and interior dimensions . All dimensions are listed
in
inches and centimeters .
HEAD HEAD
LEG SHOULDER HIP
FRONT/ REAR FRONT/ REAR
FRONT / REAR FRONT / REAR FRONT /
REAR
SOFT TOP HAR ~~ TOP
42 .3/40 .2 40 .9/391
41 .0/36 .4 51 .9/57 .3 51
.1/43 .5
107 .5 /102 .2
103 .8 / 909 .4 104 .1/92 .4 131 .9 /145 .5
129 .7 /110 .5
MODEL WHEEL TRACK TRACK
OVERALL
LENGTH
HEIGHT
NAME BASE RONT REAR
WIDTH
TJ-Wrangler 93 .4 58 .0 147 .3 58 .0
147
.3
147 .7 375 .1 66 .7 169 .3 70 .6
179
.4
237 .3

4 INTRODUCTION
GENERAL
INFORMATION (Continued)
INTERNATIONAL CONTROL AND
DISPLAY- SYMBOLS
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
The graphic symbols illustrated
in the following
chart are used to identify
various instrument con-
trols . The symbols correspond to the controls and dis-
plays that are located on the instrument panel
.
FASTENER
IDENTIFICATION
THREAD
IDENTIFICATION
SAE and metric bolt/nut threads are
not the same .
The difference is described in the
Thread Notation
chart (Fig
. 4) .
GRADE/CLASS
IDENTIFICATION
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
TJ
Fig, 4 Thread Notation-SAE and
Metric
PR606B
marks plus 2 . The most
commonly used metric bolt
strength classes are 9 .8 and 12 .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 .
= D
1
_Q_
i
HEADLIGHTS,
PARKING LIGHTS,
WINDSHIELD
HIGH BEAM
FOG LIGHTS PANEL LIGHTS TURN SIGNAL HAZARD
WARNING WASHER
13 P
WINDSCREEN
WINDSHIELD WINDSHIELD WIPER DEMISTING
REAR WINDOW REAR WINDOW
WIPER AND WASHER AND
DEFROSTING VENTILATING FAN DEFOGGER WIPER
.w .
L O W
REAR WINDOW ENGINE
COOLANT BATTERY CHARGING
WASHER
FUEL TEMPERATURE CONDITION ENGINE OIL
SEAT BELT
REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT
HOOD (TRUNK) HORN LIGHTER
J951N-23
INCH
METRIC
5/16-18
M8 X 1 .25
THREAD NUMBER
THREAD DISTANCE
MAJOR OF
MAJOR BETWEEN
DIAMETER
THREADS DIAMETER IN
THREADS IN
IN INCHES PER INCH
MILLIMETERSMILLIMETERS

TJ

INTRODUCTION 5
GENERAL
INFORMATION (~ontinued)
Bolt Head Markings
Bolt Markings and Torque - Metric
FASTENER IDENTIFICATION
Commercial Steel Class
8 .8

10 .9

12 .9
l
~~
llhlll
~
8
.s
10 .9
12 .9
Body
Size Torque Torque Torque
Diam . Cast Iron Aluminum Cast
Iron Aluminum
Cast Iron Aluminum
mm Nam ft-Ib Nam ft-lb Nam ft-Ib
Nam ft-Ib Nam
ft-Ib Nam ft-Ib
6 9 5 7 ',4
14 9 11 7
14 9 11
7
7 14 9 11 ',7 18
14 14 11
23 18 18 14
8 25 18 18
ll4 32 23 25
18 36 27 28
21
10 40 30
30 5 60 45 45 35 70
50
55 40
12
70
55
55
0 105 75 80 60
125 95
100 75
14 115 85 90 15 160 120 125
95 195 145 150 110
16 180 130 140 1 0
240 175 190 135 290
210 220 165
18 230 170 180 1 5 320
240 250 185
400 290 310
230
Bolt Markings and Torque Values - U .S .
Customary
SAE Grade Number 5 8
Bolt Head Markings
kaffii
These are all
SAE Grade
5 (3)
line i
Y
Bolt Torque - Grade 5 Bolt Bolt
Torque - Grade 8 Bolt
Body Size Cast Iron '',
Aluminum Cast Iron
Aluminum
Nam #-I4 Nam
ft-Ib Nam ft-Ib
Nam ft-Ib
11,4 -20 9 18
6 15
1 1 12 9
-28
12 09 7 18
13 14 10
5/16
-18 20 16 12 30 22
24 18
-24 23 1
1,
19 14 33 24
25 19
3/8 -16 40
3 25 20 55
40 40 30
-24 40 3
35 25 60 45 45
35
7/16 -14 60
4 45 35 90
65 65 50
-20 65 5 55 40
95 70 75
55
1/2 -13 95 70 75 55
130 95
100 75
-20 100 7 80 60
150 110
120 90
9/16 -12 135 10 110 80
190 140
150 110
-18 150 11 115 85
210 155 170 125
5/8 -11 180 13, 1 150 110
255
190 205 150
-18 210 15
160 120 290
215 230
170
3/4-10 325 240
255 190 460 340 365
270
-16 365 270
285 210 515 380 410
300
7/8 -9 490 360 380 280 745 550 600 440
-14 530 390 420 310 825 610 660 490
1 -8 720 53(~ 570 420
1100 820 890 660
-14 800 590 650 480
1200 890 960 710

6 INTRODUCTION

TJ
GENERAL INFORMATION
(Continued)
HOW TO DETERMINE BOLT STRENGTH
FASTENER STRENGTH
951N-4
Mark Class
Mark Class
Hexagon 4 - 4T Stud bolt
head bolt 5 - 5T
Bolt 6 - 6T ,
headhead No . 7 - 7T
No mark
8 - 8T
9 -
9T " .~
4T
10- 10T
11 - 11T 0
1
O
No
mark 4T
Hexagon
flange bolt
O No mark
4T Grooved
w/washer
hexagon bolt
p
6T
Hexagon
u
head bolt Two 5T O
protruding
U
lines
.Wr .
Hexagon
flange bolt Two
protruding 6T Welded bolt
w/washer lines
hexagon bolt
Hexagon
head bolt Three
0
O
o protruding 7T
a
'
lines
4T
Hexagon
head bolt Four
protruding 8T
0o
lines