Jeep Wrangler 1997 User manual

CHRYSLER

CORPORATION

SERVICE

MANUAL

1997

JEEP®

WRANGLER

order

the

special service

tools

used

and

illustrated,

please

refer

the

instructions

inside

back

cover

COR

PORATION

PART

THIS

PUBLICATION

MAY

REPRODUCED,

STORED

RETRIEVAL

SYSTEM,

TRANSMITTED,

ANY

FORM

ANY

MEANS,

ELECTRONIC,

MECHANICAL,

PHOTOCOPYING,

RECORDING,

OTHERWISE,

WITHOUT

THE

PRIOR

WRITTEN

PERMISSION

OFCHRYSLER

CORPORATION

Chrysler

Corporation

reserves

the

right

make

changes

design or

make

additions

to or

improvements

its

products

without

imposing

any

obli-

gations

upon

itself

install

them on

its

products

previously

manufactured

Litho

1996

Chrysler

Corporation

10MO196

Paper

Content

50%

Recycled

FOREWORD

The

information

contained

this

service

manual

has

beenprepared

for

the

professional

automotive

tech-

nician

involved

daily

repair

operations

This

manual

does

not

cover

theory

operation,

which

addressed

service

training

material

Information

describing

the operation

and

use

standard

and

optional

equipment

included

the

Owner's

Manual

provided

with

the

vehicle

Information

this

manual

divided

into

groups

These

groups

contain

general

information,

diagnosis,

testing,

adjustments,

removal,

installation,

disassembly,

and

assembly

procedures

for

the

systems

and

compo-

nents

assist

in locating

group

title

page,

use

the

Group

Tat)

Locator

the

following

page

The

solid

bar

after

the

group

title

aligned

solid

tab

the

first

page

each

group

The

first

page

the

group

has

contents

section

that

lists

major

topics

within

the

group

you

are not

sure

which

Group

contains

the

infor-

mation

you

need,

look

the

Component/System

the

alphabetical

index

located

the

rear

this

manual

Service

Manual

Comment

form

included

the

rear

of this

manual

Use

the

form

provide

Chrysler

Corporation

withyour

comments

and

suggestions

Tightening

torques

are

provided

specific

value

throughout

this

manual

This

value

represents

the

midpoint

the

acceptable

engineering

torque

range

for

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

removed

Chrysler

Corporation

reserves

the

right

change

testing

procedures,

specifications,

diagnosis,

repair

methods,

vehicle

wiring

any

timewithout

prior notice or

incurring

obligation

GROUP

TAB

LOCATOR

Service

Manual

Comment

Forms



(Rear

Manual)

INTRODUCTION

CONTENTS

GENERAL

INFORMATIONI

VEHICLE

IDENTIFICATION

NUMB

The

Vehicle

Identification

her

(VIN)

plate

located

the

lower windshield

ence

near

the

left

A-pillar

The

VIN

contains

characters

that

provide

data concerning

the

vehicle

Refer

the

VIN

decod-

ing

chart

determine

the

identification

vehicle

The

Vehicle

Identification

Number

also

imprinted

the

Body

Code

Plate

Vehicle

Safety

Certification

Label

Frame

rail

VEHICLE

~IDENTIFICATION

NUMBER

DECODING

CHART

INTRODUCTION

protect

the

consumer

from

theft

and

possible

fraud

the

manufacturer

required

include

Check

Digit

the

ninth

position

the

Vehicle

Iden-

tification

Number

The

check

digit

used

the

manufacturer

and

government

agencies

to verify

the

authenticity

the

vehicle

and

official

documenta-

tion

The

formula

use

the

check

digit

not

released

the

general

public

POSITION

INTERPRETATION

CODE

DESCRIPTION

ountry

Origin

United

States

Make

J =

Jeep

Vehicle

Type

MPV

Gross

Vehicle

Weight

Rating

E =

3001-4000

lbs

F =

4001-5000

lbs

Vehicle

Line

= Wrangler

4X4

Series

Sport

2=SE

4 =

Sahara

Body

Style

9 =

Open

Body

8Engine

= 2

.5L

Leaded-Gasoline

= 2

.5L

Unleaded-Gasoline

= 4

.OL

Unleaded-Gasoline

= 4

.OL

Leaded-Gasoline

Check

Digit

Model

Year

1997

ssembly

Plant

Toledo

thru

Vehicle

Seq

ence

page page

GENERAL

INFORMATION

METRIC

SYSTEM

....

..............

. .

....

BODY

CODE

PLATE

.........

........

.....

TORQUE

REFERENCES

.............

. .

....

FASTENER

IDENTIFICATION

.......... .

.....

VEHICLE

DIMENSIONS

..............

....

FASTENER

USAGE

...............

. .

.....

VEHICLE

IDENTIFICATION

NUMBER

....

. .

...

INTERNATIONAL

VEHICLE

CON ROL AND

VEHICLE

SAFETY

CERTIFICATION

LABEL

....

DISPLAY

SYMBOLS

....... .......

.....

INTRODUCTION



GENERAL

INFORMATION

(Continued)

VEHICLE

SAFETY

CERTIFICATION

LABEL

vehicle

safety

certification

label

(Fig

attached

every Chrysler

Corporation

vehicle

The

label

certifies

that

the

vehicle

conforms

all

appli-

cable

Federal

Motor

Vehicle

Safety

Standards

The

label

also

lists

Paint

and

Trim

codes



Fig

Body

Code

Plate

Location

Country

of origin

The

label

located

the

driver-side

door

shut-



PRIMARY



SECONDARY



VINYL

ROOF

PAINT

face

MFD



CHRYSLER



DATE

MFR



GUUR

CORPORATION



1X_XX



06400

2903

GAUR

FRONT



uITH

TIRES



RIMS



PSI

COLD



VEHICLE



CAR

3300

LB 1497 KG



P235/75R15X1_



15 X

.5HD



ORDER

GAUp REAR



uITH

11RES



RIMS



PSI

COLD



NUMBER



LINE

SHELL

3850

LB 1747 KG



P235/75R15XL



15 X

.5HD



PAINT



(3)

XXXX

:XXXX

XXX

XXXXXX



ENGINE

THIS

VEHICLE CONFORMS

ALL

APPLICABLE

FEDERAL

MOTOR

VEHICLE

SAFETY



PROCEDURE



(2)

xxX

XXXX XXXX XXXX

XXX

STANDARDS

EFFECT

THE

DAZE

MANUFACTURE SHOUN

ABOVE,



(1)



XxX



XXXXXXXXXXXXXXXXX



TRIM

VIN

XXXXXXXXXXXXXXXXX



TYPE



TRUCK



SINGLE



DUAL

BODY

CODE

PLATE

e020cdss

Fig

Vehicle

Safety

Certification

Label-Typical

FLOOR

PAN

SNAP

BODY

CODE

PLATE

SNAP

FWD

TRANSMISSION

VIN

MARKET

Fig

Body

Code

Plate

Decoding

BODY

CODE

PLATE-LINE

DIGITS

THROUGH

LOCATION

AND

DECODING



Vehicle

Order

Number

metal

body

code

plate

attached

the

floor

pan

under

the

drivers

seat

(Fig

Disengage

the

snaps



DIGITS

13, 14,

AND

attaching

the

carpet

the

floor

pan

read

the



Open

Space

information

There

are

seven

lines

information

the

body

code

plate

Lines

5, 6,

and

are not

used



DIGITS

16, 17,

AND

define

service

information

Information

reads

from



Car

Line

Shell

left

right,

starting

with

line

the

center

the



TJJ

Wrangler

(LHD)

plate

line

the

bottom

the



_plate

(Fig



TJU

Wrangler

(AHD)

The

last

code

imprinted

on a

vehicle

code

plate

will

followed

the

imprinted

word

END

When

two



DIGIT

vehicle

code

plates are

required,,

the

last

available



Price

Class

spaces

the

first

plate

will

imprinted

with

the



Wrangler

(All)

letters

CTD

(for

continued)

When

second

vehicle

code

plate

necessary,

the



DIGITS 20

AND

first

four

spaces

on'

each

row

will

Inot

used

because



Body

Type

the

plate

overlap



77 =

Wheel

Base

(93

931N-S

Month

and

year

vehicle

manufacture

Gross

Vehicle

Weight

Rating

(GVWR)

The

gross

front

and

rear

axle

weight

ratings

(GAWR's)

are

based

minimum

rim

size

and

maximum

cold

tire

inflation

pressure

Vehicle

Identification

Number

(VIN)

Type

vehicle

.16

Type

rear

wheels

FRONT

Bar

code

CARPET

Month,

Day

and

Hour

(MDH)

final

assembly

GENERAL

INFORMATION

(0ontinued)

BODY

CODE

PLATE-LINE

DIGITS

1,2,

AND

Paint

Procedure

DIGIT

Open

Space

DIGITS

THROUGH

Primary

Paint

Refer

Group

23,

Body

for

color

codes

DIGIT

Open

Space

DIGITS

THROUGH

Secondary

Paint

DIGIT

Open

Space

DIGITS

THROUGH

Interior

Trim

Code

DIGIT

Open

Space

DIGITS

20, 21,

AND

Engine

Code

EPE

= 2

cyl

MPI

Gasoline

ERH

4.OL 6

cyl

MPI

Gaso4ne

BODY

CODE

PLATE

LINE

DIGITS

1, 2,

AND

Transmission

Codes

DDQ

AX5

5-speed

Manual

DDO

AX15

5-speed

Manual

DGD

30RH

3-speed

Automatic

DIGIT

Open

Space

DIGIT

Market

Code

International

Canada

Mexico

United

States

DIGIT

Open

Space

VEHICLE

EXTERIOR

DIMENSIONS

VEHICLE

INTERIOR

DIMENSIONS

INTRODUCTION

DGG

32RH

3-speed

Automatic

DIGITS

THROUGH

Vehicle

Identification

Number

(VIN)

Refer

Vehicle

Identification

Number

(VIN)

para-

graph

for

proper

breakdown

VIN

code

VEHICLE

DIMENSIONS

The

vehicle

dimension

data

charts

list

the

exterior

and

interior

dimensions

All

dimensions

are

listed

inches

and

centimeters

HEAD HEAD

LEG

SHOULDER

HIP

FRONT/

REAR

FRONT/

REAR

FRONT

REAR

FRONT

REAR

FRONT

REAR

SOFT

TOP

HAR

TOP

.3/40

.9/391

.0/36

.9/57

.3 51

.1/43

107

/102

103

909

104

.1/92

131

/145

129

/110

MODEL

WHEEL

TRACK TRACK

OVERALL

LENGTH

HEIGHT

NAME

BASE

RONT REAR

WIDTH

TJ-Wrangler

147

375

169

179

237

INTRODUCTION

GENERAL

INFORMATION

(Continued)

INTERNATIONAL

CONTROL

AND

DISPLAY-

SYMBOLS

INTERNATIONAL

VEHICLE

CONTROL

AND

DISPLAY

SYMBOLS

The

graphic

symbols

illustrated

the following

chart

are

used

to identify

various

instrument

con-

trols

The

symbols

correspond

the

controls

and

dis-

plays

that

are

located

the

instrument

panel

FASTENER

IDENTIFICATION

THREAD

IDENTIFICATION

SAE

and

metric

bolt/nut

threads

are

not

the

same

The

difference

described

the

Thread

Notation

chart

(Fig

GRADE/CLASS

IDENTIFICATION

The

SAE

bolt

strength

grades

range

from

grade

The

higher

the

grade

number,

the

greater

the

bolt

strength

Identification

determined

by the

line

marks

on the

top

each

bolt

head

The

actual

bolt

strength

grade

corresponds

the

number

line

Fig,

Thread

Notation-SAE and

Metric

PR606B

marks

plus

The

most

commonly

used

metric

bolt

strength

classes

are 9

and

The

metric

strength

class identification

number

imprinted

the

head

the

bolt

The

higher

the

class

number,

the

greater

the

bolt

strength

Some

metric nuts

are

imprinted

with

single-digit

strength

class

the

nut

face

Refer

the

Fastener

Identification

and

Fastener

Strength

Charts

_Q_

HEADLIGHTS,

PARKING

LIGHTS,

WINDSHIELD

HIGH

BEAM

FOG

LIGHTS

PANEL

LIGHTS

TURN

SIGNAL

HAZARD

WARNING

WASHER

WINDSCREEN

WINDSHIELD WINDSHIELD

WIPER

DEMISTING

REAR

WINDOW

REAR

WINDOW

WIPER

AND

WASHER

AND

DEFROSTING

VENTILATING

FAN

DEFOGGER

WIPER

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

.25

THREAD

NUMBER

THREAD

DISTANCE

MAJOR

BETWEEN

DIAMETER

THREADS

DIAMETER

THREADS

INCHES

PER

INCH

MILLIMETERSMILLIMETERS



INTRODUCTION

GENERAL

INFORMATION

(~ontinued)

Bolt

Head

Markings

Bolt

Markings

and

Torque

Metric

FASTENER

IDENTIFICATION

Commercial

Steel

Class



llhlll

Body

Size

Torque Torque Torque

Diam

Cast

Iron

Aluminum

Cast

Iron

Aluminum

Cast

Iron

Aluminum

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

',7

23 18 18 14

18 18

ll4

36 27 28

40 30

45 35 70

55 40

105

80 60

125

100

115

85 90

160 120 125

195 145 150 110

180

130

140

240

175

190

135 290

210

220

165

230 170

180

320

240

250

185

400

290

310

230

Bolt

Markings

and

Torque

Values

Customary

SAE

Grade

Number

5 8

Bolt

Head

Markings

kaffii

These

are

all

SAE

Grade

(3)

line

Bolt

Torque

Grade

Bolt Bolt

Torque

Grade

Bolt

Body

Size

Cast

Iron

'',

Aluminum

Cast

Iron

Aluminum

Nam

#-I4

Nam

ft-Ib

Nam

ft-Ib

Nam

ft-Ib

11,4

-20

1 1

-28

12 09

13 14 10

5/16

-18

12 30 22

-24

14 33 24

3/8

-16

40 40

-24

25 60 45 45

7/16

-14

35 90

65 50

-20

95 70

1/2

-13

130

100

-20 100

150

110

120

9/16

-12 135

110

190

140

150 110

-18 150

115

210

155 170 125

5/8

-11

180

13,

150 110

255

190

205

150

-18 210

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

-8

720

53(~

570 420

1100

820 890 660

-14

800 590 650 480

1200

890 960 710

INTRODUCTION



GENERAL

INFORMATION

(Continued)

HOW

DETERMINE

BOLT

STRENGTH

FASTENER

STRENGTH

951N-4

Mark

Class

Mark

Class

Hexagon

Stud

bolt

head

bolt

Bolt

headhead

mark

10-

10T

11T 0

mark

Hexagon

flange

bolt

mark

Grooved

w/washer

hexagon

bolt

Hexagon

head

bolt

Two

protruding

lines

.Wr

Hexagon

flange

bolt

Two

protruding

Welded

bolt

w/washer

lines

hexagon

bolt

Hexagon

head

bolt

Three

protruding

lines

Hexagon

head

bolt

Four

protruding

lines

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