2003 Jeep Wrangler (TJ) Service & Owners Manual.pdf

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Introduction

Lubrication & Maintenance

Suspension

Differential & Driveline

Brakes

Clutch

Cooling

Audio

Chime/Buzzer

Electronic Control Modules

Engine Systems

Heated Systems

Horn

Ignition Control

Instrument Cluster

Lamps

Power System

Restraints

Speed Control

Vehicle Theft Security

Wipers/Washers

Wiring

Engine

Exhaust System

Frame & Bumpers

Fuel System

Steering

Transmission and Transfer Case

Tires/Wheels

Body

Heating & Air Conditioning

Emissions Control

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

INTRODUCTION 1

INTRODUCTION

TABLE OF CONTENTS

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.

Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL -

TYPICAL

Type of rear wheels.

Bar code.

The Vehicle Identification Number is also

imprinted on the:

Month, Day and Hour (MDH) of final assembly.

Paint and Trim codes.

Vehicle Safety Certification Label.

Country of origin.

The label is located on the driver-side door shut-

face.

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.

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.

INTRODUCTION

VEHICLE IDENTIFICATION NUMBER (Continued)

VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION

INTERPRETATION

CODE = DESCRIPTION

Country of Origin

1 = United States

Make

J = Jeep

Vehicle Type

4 = MPV

Gross Vehicle Weight Rating

E = 3001-4000 lbs.

F = 4001-5000 lbs.

Vehicle Line

A = Wrangler 4X4 (LHD)

4 = Wrangler 4X4 (RHD)

Series

2 = SE

3=X

4 = Sport

5 = Sahara

Body Style

9 = Open Body

Engine

P = 2.4L Gasoline

S = 4.0L Gasoline

Check Digit

0 through 9 or X

Model Year

3=2003

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

INTRODUCTION 3

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).

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

VKN = Hard Top White

VKU = Hard Top Spice

VKX = Hard Top Black

Fig. 3 Body Code Plate Location

DIGITS 16, 17, AND 18

Car Line Shell

TJJ = Wrangler (LHD)

1 - SNAP

2 - REAR CARPET

3 - BODY CODE PLATE

4 - SNAP

5 - FLOOR PAN

6 - FRONT CARPET

TJU = Wrangler (RHD)

DIGIT 19

Price Class

L = Wrangler (All)

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.

DIGITS 20 AND 21

Body Type

77 = Wheel Base (93.4 in.)

BODY CODE PLATE—LINE 2

DIGITS 1,2, AND 3

Paint Procedure

BODY CODE PLATE—LINE 3

DIGIT 4

Open Space

DIGITS 1 THROUGH 12

Vehicle Order Number

DIGITS 5 THROUGH 8

Primary Paint

(Refer to 23 - BODY/PAINT - SPECIFICATIONS)

for color codes.

DIGITS 13, 14, AND 15

Roof

VJN = Soft Top White

VJU = Soft Top Spice

DIGIT 9

Open Space

VJX = Soft Top Black

INTRODUCTION

BODY CODE PLATE (Continued)

DIGITS 10 THROUGH 13

Secondary Paint

DIGIT 4

Open Space

DIGIT 14

Open Space

DIGIT 5

Market Code

B = International

DIGITS 15 THROUGH 18

Interior Trim Code

DIGIT 6

Open Space

DIGIT 19

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.

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

INTERNATIONAL SYMBOLS

DIGITS 1, 2, AND 3

Transmission Codes

DDD = NV3550 5 - speed Manual

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.

DDK = AX15 5 - speed Manual

DG6 = 42RLE 4 - speed Automatic

Fig. 5 INTERNATIONAL CONTROLAND DISPLAY SYMBOLS

High Beam

Rear Window Washer

Fog Lamps

Fuel

Headlamp, Parking Lamps, Panel Lamps

Engine Coolant Temperature

Turn Warning

Battery Charging Condition

Hazard Warning

Engine Oil

Windshield Washer

Seat Belt

Windshield Wiper

Brake Failure

Windshield Wiper and Washer

Parking Brake

Windscreen Demisting and Defrosting

Front Hood

Ventilating Fan

Rear hood (Decklid)

Rear Window Defogger

Horn

Rear Window Wiper

Lighter

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