Jeep Wrangler TJ Service Manual 1997-1999

GROUP TAB LOCATOR 8L Lamps 8W Wiring Diagrams 13 Frame and Bumpers 14 Fuel System 25 Emission Control Systems

INTRODUCTION CONTENTS page page GENERAL INFORMATION BODY CODE PLATE ...................... 2 FASTENER IDENTIFICATION ................ 4 FASTENER USAGE ....................... 4 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS .................... 4 METRIC SYSTEM ........................ 7 THREADED HOLE REPAIR ................. 7 TORQUE REFERENCES .................... 9 VEHICLE DIMENSIONS .................... 3 VEHICLE IDENTIFICATION NUMBER ......... 1 VEHICLE SAFETY CERTIFICATION LABEL ..... 1 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER 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 decoding 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. 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 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: • 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). 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 Y = Wrangler 4X4 6 Series 1 = Sport 2 = SE 4 = Sahara 7 Body Style 9 = Open Body 8 Engine P = 2.5L Unleaded-Gasoline S = 4.0L Unleaded-Gasoline 9 Check Digit 10 Model Year W = 1998 11 Assembly Plant P = Toledo #2 12 thru 17 Vehicle Build Sequence TJ INTRODUCTION 1

• Type of vehicle. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin. The label is located above the door hinge on the driver-side A-pillar. BODY CODE PLATE LOCATION AND DECODING A metal body code plate is attached to the floor pan under the drivers seat (Fig. 2). 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. 3). 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. BODY CODE PLATE—LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13, 14, AND 15 Roof • VJN = Soft Top White • VJU = Soft Top Spice • VJX = Soft Top Black • VKN = Hard Top White • VKU = Hard Top Spice • VKX = Hard Top Black Fig. 1 Vehicle Safety Certification Label—Typical Fig. 2 Body Code Plate Location Fig. 3 Body Code Plate Decoding 2 INTRODUCTION TJ GENERAL INFORMATION (Continued)

DIGITS 16, 17, AND 18 Car Line Shell • TJJ = Wrangler (LHD) • TJU = Wrangler (RHD) DIGIT 19 Price Class • L = Wrangler (All) DIGITS 20 AND 21 Body Type • 77 = Wheel Base (93.4 in.) 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 = 4.0L 6 cyl. MPI Gasoline 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 • DGG = 32RH 3–speed Automatic DIGIT 4 Open Space DIGIT 5 Market Code • B = International • C = Canada • M = Mexico • U = United States DIGIT 6 Open Space 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 exterior and interior dimensions are listed in inches and centimeters. EXTERIOR DIMENSIONS Wheel Base..................93.4 in. (237.3 cm.) Track: Front .................58.0 in. (147.3 cm.) Track: Rear..................58.0 in. (147.3 cm.) Length ....................147.7 in. (375.1 cm.) Width ......................66.7 in. (169.3 cm.) Height .....................70.6 in. (179.4 cm.) INTERIOR DIMENSIONS Head Room: Soft Top-Front .....42.3 in. (107.5 cm.) Head Room: Soft Top-Rear ......40.2 in. (102.2 cm.) Head Room: Hard Top-Front ....40.9 in. (103.8 cm.) Head Room: Hard Top-Rear ......39.1 in. (99.4 cm.) Leg-Front ...................41.0 in. (104.1 cm.) Leg-Rear ....................36.4 in. (92.4 cm.) Shoulder-Front ...............51.9 in. (131.9 cm.) Shoulder-Rear ...............57.3 in. (145.5 cm.) Hip-Front ...................51.1 in. (129.7 cm.) Hip-Rear ....................43.5 in. (110.5 cm.) TJ INTRODUCTION 3 GENERAL INFORMATION (Continued)

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS The graphic symbols illustrated in the following chart (Fig. 4) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. FASTENER IDENTIFICATION FASTENER IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt/nut threads are not the same. The difference is described in the Thread Notation chart (Fig. 5). 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 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. FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig. 4 Fig. 5 Thread Notation—SAE and Metric 4 INTRODUCTION TJ GENERAL INFORMATION (Continued)

FASTENER IDENTIFICATION TJ INTRODUCTION 5 GENERAL INFORMATION (Continued)

FASTENER STRENGTH 6 INTRODUCTION TJ GENERAL INFORMATION (Continued)

for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoilt. Follow the manufactures recommenda- tions for application and repair procedures. METRIC SYSTEM The metric system is based on quantities of one, ten, one hundred, one thousand and one million (Fig. 6). The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. 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.) Fig. 6 Metric Prefixes CONVERSION FORMULAS AND EQUIVALENT VALUES TJ INTRODUCTION 7 GENERAL INFORMATION (Continued)

METRIC CONVERSION 8 INTRODUCTION TJ GENERAL INFORMATION (Continued)

Jeep Wrangler TJ Service Manual 1997-1999

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