1997-2006 Jeep Wrangler (TJ) Service & Repair Manual
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GROUP TAB LOCATOR Service Manual Comment Forms (Rear of Manual)
TJ INTRODUCTION CONTENTS GENERAL INFORMATIONII 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 8 Engine 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 e nce 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 O O 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 13P WINDSCREEN WINDSHIELD WINDSHIELD WIPER DEMISTING REAR WINDOW REAR WINDOW WIPER AND WASHER AND DEFROSTING VENTILATING FAN DEFOGGER WIPER .w. L OW 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 MILLIMETERS MILLIMETERS
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 , head head 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 0 o lines
TJ GENERAL INFORMATION (~ontinued) FASTENER USAGE WARNING : USE OF AN INCO RECT FASTENER MAY RESULT IN COMPONENT IMAGE OR PER- SONAL INJURY. Figure art, specifications and t this Service Manual are identified format . During any maintenance or rep important to salvage all fastener for reassembly. If the fastener is fastener of equivalent specificatio~h rque references in in metric and SAE it procedures, it is s (nuts, bolts, etc .) not salvageable, a should be used . METRIC SYSTEM The metric system is based o ten, one hundred, one thousand a 5) . The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa . quantities of one, d one million (Fig . Fig. 5 Metric Prefixes CONVEOSION FORMULAS AND EQUIVALENT VALUES INTRODUCTION 7 Mega - (M) Million Deci - (D) Tenth Kilo - (K) Thousand Centi - (C) Hundreth Milli - (m) Thousandth J901 N-2 Refer to the 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 .) TORQUE REFERENCES Individual Torque Charts appear at the end of many Groups . Refer to the Standard Torque Specifi- cations Chart for torque references not listed in the individual torque charts . J91IN-1 Multiply sly o Get Multiply By To Get in-Ibs x .11298 Newton-Meters (N "m) N-m x8 .851 = In-Ibs ft-Ibs x 1 .3558 Newton-Meters (N-m) N"m x0 .7376 = ft-Ibs Inches Hg (60°F) x 3.377 Kilopascals (kPa) kPo x0 .2961 = Inches Hg psi x 6.895 Kilopascals (kPa) kPa x0.145 = psi Inches x 25.4 b Millimeters (mm) mm x 0.03937 Inches Feet x 0.3048 Meters (M) M x3.281 Feet Yards x0 .9144 Meters (M) M x 1 .0936 Yards Miles x 1 .6093 Kilometers (Km) Km x0.6214 Miles mph x 1 .6093 Kilometers/Hr. (Km/h) Km/h x0 .6214 = mph Feet/Sec . x 0.3048 Meters/Sec . (M/S) M/S x3.281 = Feet/Sec. Kilometers/Hr . x 0.27778 Meters/Sec . (M/S) WS x 3.600 = Kilometers/Hr . mph x 0 .4470 Meters/Sec . (M/S) WS x 2.237 - mph 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
1997-2006 Jeep Wrangler (TJ) Service & Repair Manual
Engines Covered:
2.5L Inline-4
4.0L Inline-6
Transmissions Covered:
AX5 5-speed manual transmission
AX15 5-speed manual transmission
30RH / 32RH 3-speed automatic transmission
This 1997-2006 Jeep Wrangler (TJ) Service & Repair Manual delivers comprehensive maintenance and repair information direct from factory sources. It applies to all TJ models powered by either the 2.5L or 4.0L engine and provides precise instructions for all supported transmission combinations.
Inside you'll find complete teardown guides, wiring schematics, troubleshooting charts, and service intervals for every major mechanical and electrical system. Whether you're performing routine maintenance or a full driveline rebuild, this manual offers the clarity and reliability needed for accurate work.
Content Overview:
Factory Maintenance & Lubrication Schedules
Engine Repair (2.5L I4 & 4.0L I6)
Ignition, Fuel, and Emission Control Systems
Manual & Automatic Transmission Overhaul
Clutch, Transfer Case & Axle Servicing
Suspension, Steering & Braking Systems
Cooling and Exhaust System Repairs
Body, Frame, Interior & HVAC Components
Lighting, Gauges, and Electrical Diagnostics
Wiring Diagrams and Fuse System Layouts
Whether you're restoring a trail rig or maintaining a daily driver, this OEM-based manual gives you the tools to keep your Wrangler TJ running strong and reliable.
Printable: Yes Language: English Compatibility: Windows, macOS, Linux Requirements: PDF reader software
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1997-2006 Jeep Wrangler (TJ) Service & Repair Manual