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  9. Jeep Wrangler 1997 User manual

Jeep Wrangler 1997 User manual

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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