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

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daimler-chrysler
GROUP TAB LOCATOR
0
2
3
5
Brakes
6
Clutch
7
Cooling
8A
Audio
8B
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
9
Engine
11
13
14
19
21
22
23
Body
24
25
Service Manual Comment Forms
(Rear of Manual)
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TJ
INTRODUCTION 1
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:
²
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.
²
Vehicle Identification Number (VIN).
²
Type of vehicle.
Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL -
TYPICAL
²
Type of rear wheels.
²
Bar code.
The Vehicle Identification Number is also
imprinted on the:
²
²
Month, Day and Hour (MDH) of final assembly.
²
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.
²
²
²
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2
INTRODUCTION
TJ
VEHICLE IDENTIFICATION NUMBER (Continued)
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:
²
Engine family and displacement
²
Evaporative family
²
Emission control system schematic
²
Certification application
²
Engine timing specifications (if adjustable)
²
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.
²
Fig. 2 VECI Label Location
1 - VECI LABEL
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TJ
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
²
VKN = Hard Top White
²
VKU = Hard Top Spice
²
VKX = Hard Top Black
Fig. 3 Body Code Plate Location
DIGITS 16, 17, AND 18
Car Line Shell
²
TJJ = Wrangler (LHD)
1 - SNAP
2 - REAR CARPET
3 - BODY CODE PLATE
4 - SNAP
5 - FLOOR PAN
6 - FRONT CARPET
²
TJU = Wrangler (RHD)
DIGIT 19
Price Class
²
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
²
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
²
VJN = Soft Top White
²
VJU = Soft Top Spice
DIGIT 9
Open Space
²
VJX = Soft Top Black
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4
INTRODUCTION
TJ
BODY CODE PLATE (Continued)
DIGITS 10 THROUGH 13
Secondary Paint
DIGIT 4
Open Space
DIGIT 14
Open Space
DIGIT 5
Market Code
²
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
²
ED1 = 2.4L 4 cyl. MPI Gasoline
²
ERH = 4.0L 6 cyl. MPI Gasoline
BODY CODE PLATE—LINE 1
INTERNATIONAL SYMBOLS
DIGITS 1, 2, AND 3
Transmission Codes
²
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.
²
DDK = AX15 5 - speed Manual
²
DG6 = 42RLE 4 - speed Automatic
Fig. 5 INTERNATIONAL CONTROLAND 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
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