Table Of Contents - Jeep Wrangler 1997 Manual

Table of Contents

Group Tab Locator1
Contents3
General Information3
Vehicle Identification Number3
Vehicle Identification Number Decoding Chart3
Vehicle Safety Certification Label4
Body Code Plate4
Location And Decoding4
Body Code Plate - Line 34
Vehicle Dimensions5
Vehicle Exterior Dimensions5
Vehicle Interior Dimensions5
International Control And Display Symbols6
International Vehicle Control And Display Symbols6
Thread Identification6
Grade/Class Identification6
Fastener Identification7
Bolt Markings And Torque - Metric7
Fastener Strength8
How To Determine Bolt Strength8
Fastener Usage9
Metric System9
Torque References9
Conversion Formulas And Equivalent Values9
Metric Conversion10
Torque Specifications11
Specified Torque For Standard Bolts11
Lubrication And Maintenance13
Parts And Lubricant Recommendations13
Internatinoal Symbols13
Classification Of Lubricants14
Api Quality Classification14
Gear Lubricants14
Fluid Capacities14
Maintenance Schedules15
Emission Control System Maintenance15
Unsheduled Inspection15
At Each Stop For Fuel15
37.500 Miles (60 000 Km) Or At 30 Months16
45.000 Miles (72 000 Km) Or At 36 Months16
52.500 Miles (84 000 Km) Or At 42 Months16
60.000 Miles (96 000 Km) Or At 48 Months16
Jump Starting Procedure20
To Jump Start A Disabled Vehicle20
Jumper Cable Clamp Connections20
Disconnect Cable Clamps21
Towing Recommendations21
Safety Precautions21
Ground Clearance21
Towing-Front End Lifted (Sling-Type)22
Emergency Tow Hooks22
Hoisting Recommendations22
Floor Jack22
Hoist23
Suspension25
Alignment25
Wheel Alignment25
Suspension And Steering System Diagnosis27
Pre-Alignment Inspection27
Alignment Measurements And Adjustments28
Camber28
Caster28
Toe Position28
Alignment Specifications29
Front Suspension30
Shock Diagnosis30
Shock Absorber31
Coil Spring31
Steering Knuckle31
Lower Suspension Arm31
Upper Suspension Arm32
Axle Bushing32
Upper & Lower Suspension Arms32
Bushing Removal32
Stabilizer Bar33
Track Bar33
Hub Bearing34
Wheel Mounting Studs34
Wheel Stud Removal34
Specifications35
Torque Chart35
Special Tools35
Rear Suspension36
Brakes41
Base Brake System41
Table Of Contents41
Brake System42
Service Warnings & Cautions42
Brake Pedal42
Stop Lamp Switch42
Description And Operation42
Master Cylinder43
Power Brake Booster-Typical43
Combination Valve44
Front Disc Brakes44
Rear Drum Brake44
Brake Caliper Operation44
Parking Brake Operation45
Parking Brake Components45
Brake Hoses And Lines46
Preliminary Brake Check46
Road Testing46
Low Pedal46
Pedal Pulsation47
Brake Drag47
Brake Fade47
Brake Pull47
Red Brake Warning Lamp48
Brake Chatter48
Thump/Clunk Noise48
Brake Lining Contamination48
Master Cylinder/Power Booster49
Power Booster Vacuum Test49
Power Booster Check Valve Test49
Metering Valve49
Disc Brake Rotor50
Rotor Minimum Thickness50
Rotor Runout50
Rotor Thickness Variation50
Brake Drum50
Brake Drum Runout51
Parking Brake51
Brake Line And Hoses51
Brake Fluid Contamination51
Brake Fluid Level52
Brake Bleeding52
Manual Bleeding52
Disc Rotor Machining52
Service Procedures52
Brake Line52
Brake Drum Machining53
Typical Fluid Container And Bleed Hose Setup53
Rotor Refinishing53
Flaring Procedure54
Inverted Flare Tools54
Removal And Installation54
Push Rod Attachment55
Combination Valve/Master Cylinder55
Combination Valve Bracket55
Power Brake Booster56
Push Rod & Clip56
Booster Mounting Nuts56
Disc Brake Caliper57
Disc Brake Shoes57
Bottoming Caliper Piston With C-Clamp57
Caliper Mounting Bolts57
Caliper Removal58
Outboard Brake Shoe Removal58
Inboard Brake Shoe Removal58
Caliper Lubrication Points58
Drum Brake Shoes59
Caliper Installation59
Mounting Bolt Dimensions59
Rotor & Hub59
Wheel Cylinder60
Drum Brake Components - Typical60
Shoe Contact Surfaces60
Parking Brake Hand Lever61
Rear Parking Brake Cable61
Parking Brake Cable Attachment61
Parking Brake Lever61
Master Cylinder Reservoir62
Cable Retainer62
Loosening Reservoir62
Disassembly And Assembly62
Grommet Removal63
Grommet Installation63
Padding Caliper Interior63
Caliper Piston Removal63
Caliper Piston Dust Boot Removal64
Piston Seal Removal64
Bushings And Boots Installation64
Piston Seal Installation64
Caliper Cleaning65
Caliper Inspection65
Piston Dust Boot Installation65
Cleaning And Inspection65
Parking Brake Cable Tensioner67
Adjustment With Brake Gauge67
Tensioner Rod Measurement67
Adjusting Gauge On Drum67
Adjustment With Adjusting Tool68
Brake Fluid68
Brake Components68
Brake Adjustment68
Antilock Brakes70
Antilock Brake System70
Normal Braking71
Antilock Braking71
Controller Antilock Brakes71
Hydraulic Control Unit71
Wheel Speed Sensors And Tone Wheel72
Speed Sensor Air Gap72
Pressure Decrease72
Pressure Hold72
Acceleration Switch73
Abs System Relays73
Abs Warning Lamp73
Bleeding Abs Brake System73
Hydraulic Controller Unit74
Front Wheel Sensor74
Hcu Brake Lines74
Hcu Mount74
Rear Wheel Speed Sensor75
Front Wheel Speed Sensor75
Setting Air Gap On Original Rear Sensor75
New Rear Sensor75
Acceleration Switch Position Indicator77
Clutch79
Clutch Components79
Hydraulic Linkage Components79
Installation Method And Parts Usage79
By-Pass Procedure80
Clutch Operation80
Clutch Contamination80
Clutch Interlock Safety Switch80
Diagnosis And Testing Diagnostic Information80
Clutch Components And Inspection81
Clutch Misalignment82
Flywheel Runout82
Clutch Cover And Disc Runout82
Clutch Housing Misalignment82
Clutch Component Lubrication87
Clutch Linkage Fluid87
Clutch Fluid Level87
Flywheel87
Clutch Cover And Disc88
Release Bearing89
Clutch Disc And Pressure Plate Inspection89
Typical Method Of Aligning Clutch Disc89
Release Bearing Attachment89
Pilot Bearing90
Clutch Housing90
Clutch Hydraulic Linkage90
Pilot Bearing Installation90
Clutch Pedal91
Right Hand Drive Clutch Master Cylinder91
Clutch Pedal Mounting91
Clutch Pedal Mounting - Right Hand Drive92
Torque92
Cooling System93
Cooling System Components94
System Coolant Routing94
Water Pump94
Coolant94
Engine Accessory Drive Belts94
Engine Block Heater95
Transmission Oil Cooler95
Coolant Flow95
Water-To-Oil Cooler95
Radiator95
Coolant Reserve/Overflow System96
Block Heater96
Thermostat96
Coolant Performance96
Coolant Selection And Additives97
Radiator Pressure Cap97
Cooling System Hoses97
Viscous Fan Drive98
Hose Clamp Tool98
Clamp Number/Letter Location98
On-Board Diagnostics (Obd)99
Water Pump Mounted Fan Drive99
Powertrain Control Module (Pcm)99
Diagnosis And Testing99
Accessing Diagnostic Trouble Codes100
Erasing Trouble Codes100
Loose Impeller100
Water Pump Test100
Accessory Drive Belt100
Impeller Test101
Serpentine Belt Wear Patterns101
Serpentine Drive Belt Diagnosis102
Preliminary Checks104
Engine Cooling System Overheating104
Trailer Towing104
Recent Service Or Accident Repair104
Cooling System Diagnosis105
Radiator Coolant Flow Check111
Testing Cooling System For Leaks111
Ultraviolet Light Method111
Pressure Tester Method111
Internal Leakage Inspection112
Combustion Leakage Test (Without Pressure Tester)112
Leaks112
Testing112
Radiator Cap-To-Filler Neck Seal - Pressure Relief Check113
Pressure Testing Radiator Caps114
Low Coolant Level Aeration114
Routing Coolant Level Check114
Coolant Service114
Deaeration114
Adding Additional Coolant115
Service Coolant Level115
Draining Cooling System115
Refilling Cooling System115
Reverse Flushing115
Reverse Flushing Engine116
Automatic Transmission Oil Cooler116
Auxiliary Transmission Oil Cooler116
Coolant Reserve/Overflow Bottle116
Removal And Installation Automatic Transmission Oil Cooler116
Reverse Rotating Water Pump117
Fan Mounting Nuts117
Power Steering Pump Attachment118
Water Pump Remove/Install119
Thermostat Removal/Installation120
Thermostat Recess120
Fan122
Block Heater And Cord122
Serpentine Drive Belt123
Belt Schematics123
Fan Blade124
Power Steering Pump Bracket And Idler Pulley124
Cooling System Capacities125
Belt Tension126
Differential And Driveline127
Propeller Shafts127
Universal Joints128
Lubrication128
Precautions128
Single Cardan Universal Joint128
Vibration129
Unbalance129
Reference Marks On Yokes129
Double Cardan (Cv) Universal Joint129
Driveline Vibration130
Runout130
Clamp Screw At Position 1130
Universal Joint Angle131
Runout Specifications131
Maximum Angles And Engine Speed131
Inspection131
Front Propeller Shaft131
Front Angle Measurement132
Rear Angle Measurement132
Universal Joint Angle Example133
Single Cardan134
Rear Propeller Shaft134
Remove Snap Ring135
Press Out Bearing135
Press Out Remaining Bearing135
Install Cross In Yoke135
Double Cardan (Cv)136
Install Bearing On Trunnion136
Install Bearing Assembly137
Press In Bearing Assembly137
Single And Double Cardan Joint138
Adjustment With Cams139
Seal Snap Rings In Groove139
Check Assembly139
Angle Adjustment With Cams139
Propeller Shafts And U-Joints140
Propeller Shaft140
Fbi Front Axle141
181 Fbi Front Axle141
Lubrication Specifications141
Axles142
Identification142
Standard Differential Operation142
Diagnostic Information142
Gear And Bearing Noise143
Low Speed Knock143
Driveline Snap143
Front Drive Axle144
Lubricant Change146
Drive Axle Assembly Replacement146
Typical Housing Cover With Sealant146
Hub Bearing And Axle Shaft147
Steering Knuckle And Ball Studs147
Hub, Knuckle And Axle Shaft147
Knuckle Removal148
Upper Ball Stud Replacement148
Lower Ball Stud Replacement148
Knuckle Installation148
Axle Bushing Replacement149
Pinion Seal149
Lower Ball Stud Remove/Install149
Pinion Yoke, Remove150
Seal Removal150
Pinion Seal Installation150
Check Pinion Rotation Torque150
Differential151
Tightening Pinion Shaft Nut151
Bearing Cap Identification151
Install Axle Housing Spreader151
Differential Installation152
Install Dial Indicator152
Spead Axle Housing152
Differential Case And Side Bearings152
Differential Side Bearings153
Differential Side Bearing Installation153
Inner Axle Shaft Oil Seal Replacement153
Pinion Gear153
Install Differential Side Bearings154
Axle Seal Installation154
Pinion Yoke Holder154
Pinion Yoke Removal154
Front Bearing Cup Removal155
Rear Bearing Cup Removal155
Collapsible Spacer155
Inner Bearing Removal155
Pinion Gear Installation156
Pinion Inner Bearing Cup Installation156
Pinion Outer Bearing Cup Installation156
Final Assembly157
Pinion Yoke Installation157
Tightening Pinion Nut157
Axle Shaft - Cardan U-Joint158
Check Pinion Gear Rotation Torque158
Axle Shaft Outer U-Joint158
Standard Differential159
Yoke Bearing Cap Removal159
Mate Shaft Roll Pin Removal159
Pinion Mate Gear Removal159
Differential Assemble160
Cardan U-Joint160
Pinion Gear Depth160
Pinion Gear Depth Variance161
Shim Locations161
Pinion Depth Measurement And Adjustment162
Pinion Gear Depth Gauge Tools162
Gauge Tools In Housing162
Differential Bearing Preload And Gear Backlash163
Differential Preload And Gear Backlash Shim Selection163
Pinion Gear Depth Measurement163
Axle Adjustment Shim Locations163
Tighten Bolts Holding Bearing Caps164
Seat Pinion Side Differential Dummy Side Bearing164
Seat Ring Gear Side Differential Dummy Side Bearing164
Differential Side Play Measurement164
Hold Differential Case And Read Dial Indicator165
Hold Differential Case And Zero Dial Indicator165
Gear Contact Pattern Analysis166
Ring Gear Backlash Measurement166
Backlash Shim Adjustment166
Gear Tooth Contact Patterns167
194 Rbi Rear Axle172
Axle Adjustment Shims And Spacer172
Lubricant Specifications173
Trac-Lok Operation173
Trac-Lok Noise Diagnosis179
Differential Test179
Trac-Lok Test179
Rear Axle180
Pinion Nut180
Differential Bearing Removal186
Ring Gear Removal186
216 Rbi Rear Axle207
Battery243
Low-Maintenance Battery243
Battery Description And Operation244
Battery Size And Ratings244
Cold Cranking Amperage244
Reserve Capacity245
Ampere-Hours245
Battery Mounting245
Built-In Test Indicator245
Abnormal Battery Discharging247
Built-In Indicator247
Hydrometer Test247
Built-In Test Indicator Sight Glass248
Open-Circuit Voltage Test249
Load Test249
Testing Open-Circuit Voltage249
Volt-Ammeter-Load Tester250
Volt-Ammeter-Load Tester Connections250
Remove Surface Charge From Battery250
Ignition-Off Draw Test251
Battery Charging251
Charging A Completely Discharged Battery252
Voltmeter Accurate To 1/10 Volt Connected252
Charging Time Required253
Remove Battery Terminal Clamp253
Clean Battery Cable Terminal Clamp253
Battery Hold-Down254
Removing Cell Caps254
Clean Battery254
Clean Battery Terminal Post255
Battery Cables255
Starting Systems257
Starter Relay258
Starting System258
Starting System Inspection259
Starting System Diagnosis260
Cold Cranking Test261
Feed Circuit Tests261
Volts-Amps Tester Connections261
Test Battery Negative Connection Resistance262
Test Battery Positive Connection Resistance262
Test Battery Positive Cable Resistance262
Test Starter Ground262
Control Circuit Tests263
Solenoid Test263
Relay Test263
Relay Circuit Test263
Park/Neutral Position Switch Test264
Clutch Pedal Position Switch Test264
Ignition Switch Test264
Starter Noise - 2.5L Engine264
Starter Shim265
Starter Noise Diagnosis265
Starter Removal/Install265
Power Distribution Center266
Charging System Operation267
Generator268
Battery Temperature Sensor268
Voltage Regulator268
Charging System Diagnosis And Testing268
Charging System Resistance Tests269
Generator Terminals269
Current Output Test270
On-Board Diagnostic Test For Charging System271
Diagnostic Trouble Codes271
Obtaining Diagnostic Trouble Codes272
Using Drb Scan Tool272
Using The Vehicle Odometer272
Charging System Diagnostic Trouble Code Descriptions272
Generator Ratings274
Ignition System275
Powertrain Control Module276
Distributor276
Spark Plugs276
Powertrain Control Module Location276
Spark Plug Cables277
Ignition Coil277
Automatic Shutdown (Asd) Relay277
Crankshaft Position Sensor277
Camshaft Position Sensor278
Sensor Operation278
Throttle Position Sensor279
Intake Manifold Air Temperature Sensor279
Ignition Switch And Key Lock Cylinder279
Automatic Shutdown (Asd) Relay Test279
Engine Coolant Temperature Sensor279
Check Coil Test280
Checking For Spark280
Failure To Start Test281
Distributor Cap281
Pcm And Three 32-Way Connectors281
Special Jumper Ground-To-Coil Negative Terminal281
Distributor Rotor282
Map Sensor282
Crankshaft Position Sensor Test282
Crankshaft Position Sensor Connector283
View Looking Into Sensor Pigtail Electrical Connector283
Spark Plug Conditions285
Cold Fouling/Carbon Fouling285
Wet Fouling Or Gas Fouling285
Oil Or Ash Encrusted285
Electrode Gap Bridging286
Scavenger Deposits286
Chipped Electrode Insulator286
Spark Plug Overheating287
Plug Cleaning288
Plug Gap Adjustment288
Spark Plug Gap288
Plug Installation288
Sensor290
Engine Firing Order-2 .5L 4-Cylinder296
Engine296
Engine Firing Order-4 .Ol 6-Cylinder296
Ignition Timing296
Instrument Panel Systems299
General Information Introduction299
Instrument Panel300
Instrument Clusters300
Gauges301
Indicator Lamps301
Fuseblock Module301
Coolant Temperature Gauge301
Fuel Gauge302
Odometer/Trip Odometer302
Oil Pressure Gauge302
Speedometer302
Tachometer303
Voltmeter303
Airbag Indicator Lamp303
Anti-Lock Brake System Lamp303
Brake Warning Lamp304
Check Gauges Lamp304
Cigar Lighter/Power Outlet304
Cluster Illumination Lamps304
Four-Wheel Drive Indicator Lamps304
Full Time305
Headlamp High Beam Indicator Lamp305
Low Fuel Warning Lamp305
Malfunction Indicator Lamp305
Master Lighting Indicator Lamp305
Seat Belt Reminder Lamp305
Turn Signal Indicator Lamps306
Upshift Indicator Lamp306
Actuator Test307
Instrument Cluster Actuator Test308
Odometer - Trip Odometer309
Accessory Relay Test312
Accessory Relay Circuit Test312
Accessory Switch Bezel319
Cluster Bulb Locations319
Center Bezel Remove/Install319
Cluster Lens319
Accessory Relay320
Glove Box Components320
Glove Box Latch Striker321
Glove Box Door/Bin321
Glove Box Latch And Handle321
Glove Box Lock Cylinder321
Grab Handle Bezel322
Instrument Panel Assembly322
Glove Box322
Steering Column Shrouds Remove/Install323
Steering Column Mounting323
Instrument Panel Base324
Passenger Airbag Module Lower Bracket Nuts324
Audio Systems325
Radios325
Ignition-Off Draw Fuse325
Speakers325
Antenna326
Radio Noise Suppression326
Audio System326
Audio System Diagnosis327
Radio328
Radio Frequency Interference330
Anti-Theft Security Code330
Sound Bar332
Horn Systems335
Horn Relay335
Horn Switch335
Horns335
Turn Signal And Hazard Warning Systems339
Combination Flasher339
Multi-Function Switch340
Turn Signal Lamps340
Wiper And Washer Systems345
Windshield Wiper System345
Windshield Washer System345
Rear Wiper And Washer System346
Wiper Arms And Blades346
Wiper Linkage And Pivots346
Wiper Motors346
Wiper And Washer Switches347
Washer Reservoir347
Washer Pumps347
Washer Nozzles And Plumbing347
Wiper Systems348
Windshield Washer Nozzles348
Rear Washer Hose Cap348
Washer Systems349
Wiper Blades And Elements351
Windshield Wiperlwasher Switch Continuity351
Rear Wiperlwasher Switch Continuity351
Wiper Arms352
Wiper Arm Remove/Install352
Front Wiper Arm Installation352
Wiper Motor353
Cowl Plenum Cover/Grille Panel Remove/Install353
Wiper Linkage Assembly Remove/Install353
Lamps357
Lamp Diagnosis357
Headlamp Diagnosis358
Fog Lamp Diagnosis359
Daytime Running Lamp Diagnosis360
Headlamp Alignment361
Headlamp Alignment Preparation361
Alignment Screen Preparation362
Headlamp Adjustment362
Headlamp Adjustment Screws362
Fog Lamp Adjustment363
Special Tools-Headlamp Alignment363
Lamp Bulb Service364
Headlamp Bulb364
Fog Lamp Bulb364
Front Park/Turn Signal Lamp Bulb364
Back-Up Lamp Bulb365
Center High Mounted Stop Lamp (Chmsl) Bulb365
Underhood Lamp Bulb365
Dome Lamp365
Lamp Service366
Fog Lamp366
Front Park[Turn Signal Lamp367
Side Marker Lamp367
Tail/Stop/Turn Signal/Back-Up Lamp367
Center High Mounted Stop Lamp (Chmsl)367
Underhood Lamp368
Sound Bar Dome Lamp (Removal368
Sound Bar Dome Lamp Installation369
Cargo Area Dome Lamp Removal369
Cargo Area Dome Lamp Installation369
Lamp Systems370
Daytime Running Lights (Canada Only)370
Daytime Running Lamp (Drl) Module370
Bulb Application371
Interior Lamps371
Exterior Lamps371
Passive Restraint Systems373
Airbag Module374
Passenger Side374
Storage374
Impact Sensor374
Clockspring375
Airbag System375
Clean-Up Procedure376
Wear Safety Glasses And Rubber Gloves376
Vacuum Heater And Aic Outlets376
Driver Airbag Trim Cover And Horn Switch378
Passenger Airbag Door379
Airbag Control Module380
Clockspring Centering381
Electrically Heated Systems383
Rear Glass Heating Grid383
Defogger Switch384
Defogger Relay384
Defogger System384
Chime/Buzzer Warning Systems389
Driver Seat Belt Switch390
Key-In Ignition Switch390
Headlamp Switch390
Driver Door Jamb Switch390
Chime Warning System Switches392
Wiring Diagrams393
8W-01 General Information395
How To Use This Group395
Connector/Ground Locations395
Splice Locations395
Wire Code Identification396
Circuit Identification396
Wire Color Code Chart396
Connectors397
Take Outs397
Symbols397
Legend Of Symbols Used On Wiring Diagrams398
Electrostatic Discharge (Esd) Sensitive Devices399
Troubleshooting Tools399
Intermittent And Poor Connections399
Checking For Terminal Spreading400
Troubleshooting Tests400
Testing For Voltage400
Testing For Continuity400
Troubleshooting Wiring Problems401
Wiring Repair401
Terminal/Connector Repair-Molex Connectors401
Terminal/Connector Repair-Thomas And Betts Connectors402
Connector Replacement402
Connector And Terminal Replacement403
Connector Locking Wedge403
Terminal Removal403
Terminal Removal Using Special Tool403
Terminal Replacement404
Diode Replacement404
Wiring/Terminal405
Diode Identification405
8W=02 Component Index407
8W-10 Fuse/Fuse Block409
8W-11 Power Distribution419
8W-15 Ground Distribution435
8W-20 Charging System443
Wiring Diagram Index443
8W-21 Starting System447
8W-30 Fuel/Ignition Systems451
8W-31 Transmission Control System471
Torque Converter Clutch (Tcc) Solenoid471
Four-Wheel Drive (4Wd) Switch471
Shift Interlock471
8W-35 All-Wheel Anti-Lock Brakes475
Wheel Speed Sensors475
G-Switch475
Abs Main Relay475
Abs Warnin Lamp476
Stop Lamp Switch Input476
Data Link Connector476
Sw-40 Instrument Cluster483
Warning Lamps-Except Abs And Brake483
8W-40 Instrument Cluster486
8W-41 Horn/Cigar Lighter495
8W-42 Air Condition Ing/Fieater499
Blower Motor499
A/C Operation499
8W-43 Airbag System505
8W-44 Interior Lighting509
8W-47 Audio System515
8W-48 Rear Window Defogger521
8W-50 Front Lighting525
8W-51 Rear Lighting533
8W-52 Turn Signals539
8W-53 Wipers545
8W-70 Splice Information553
8W-80 Connector Pin-Outs581
8W-90 Connector Locations619
8W-95 Splice Locations639
Emission Control Systems649
Malfunction Indicator Lamp (Mil)649
State Display Test Mode650
Circuit Actuation Test Mode650
Using Orb Scan Tool650
Using The Malfunction Indicator Lamp (Mil)651
Monitored Systems655
Dtc 21-Oxygen Sensor (02S) Monitor655
Dtc 21-Oxygen Sensor Heater Monitor655
Dtc 43-Misfire Monitor656
Dtc 51/52-Fuel System Monitor656
Dtc 64-Catalyst Monitor656
Trip Definition656
Component Monitors657
Non-Monitored Circuits657
Pcm System Ground658
Pcm Connector Engagement658
High And Low Limits658
Evaporative Emission Controls659
Evaporation (Evap) Control System659
Rollover Valve659
Evap Canister659
Fuel Tank Filler Tube Cap660
Crankcase Ventilation System660
Vehicle Emission Control Information (Veci) Label661
Vacuum Schematics661
Evap Canister Purge Solenoid662
Form-In-Place Gaskets663
Mopar Gasket Maker663
Surface Preparation663
Engine Performance664
Honing Cylinder Bores664
Measuring With Plastigage665
Crankshaft Main Bearing Clearance665
Connecting Rod Bearing Clearance666
Repair Damaged Or Worn Threads666
Service Engine Assembly (Short Block)666
Hydrostatic Lock666
Engine Oil Specification667
Api Service Grade Certified667
Sae Viscosity667
Energy Conserving Oil667
Engine Oil Change668
Engine Oil Filter Change668
Filter Specification668
Oil Filter Removal669
Oil Filter Installation669
Used Engine Oil Disposal669
Engine Diagnosis670
Hydraulic Tappets670
Leak-Down Test670
Intake Manifold Leakage Diagnosis671
Cylinder Compression Pressure Test671
Engine Cylinder Head Gasket Failure Diagnosis671
Cylinder-To-Cylinder Leakage Test671
Inspection (Engine Oil Leaks -In General)672
Air Leak Detection Test Method672
Inspection For Rear Seal Area Leaks672
Engine Oil Pressure673
Service Diagnosis-Performance674
Engine Description678
Build Date Code679
Build Date Code Location679
Oil Lubrication System680
Oil Pump Pressure681
Oversize And Undersize Component Codes681
Valve Timing681
Piston Fitting681
Piston Size Chart682
Piston Ring Fitting682
Ring Side Clearance Measurement682
Piston Dimensions682
Ring Gap Measurement683
Compression Ring Installation683
Piston Ring End Gap Position683
Fitting Connecting Rod Bearings684
Connecting Rods684
Bearing-To-Journal Clearance684
Side Clearance Measurement685
Connecting Rod Bearing Fitting Chart685
Measuring Bearing Clearance With Plastigage685
Fitting Crankshaft Main Bearings686
Fitting Bearings (Crankshaft Installed)686
Bearing-To-Journal Clearance (Crankshaft Installed)686
Main Bearing Journal Diameter687
Main Bearing Fitting Chart688
Engine Mounts-Front689
Engine Mount-Rear689
Engine Assembly690
Fuel Line Quick-Connect Couplings691
Cylinder Head Cover692
Rocker Arms And Push Rods693
Valve Springs And Oil Seals693
Rocker Arm Assembly693
Engine Cylinder Head694
Valve And Valve Components694
Fabricate Alignment Dowels695
Alignment Dowel Locations695
Valves And Valve Springs696
Vibration Damper697
Timing Case Cover Oil Seal698
Timing Case Cover698
Timing Chain And Sprockets699
Loading Timing Chain Tensioner700
Camshaft Pin Replacement701
4.Ol Engine715
Exhaust System And Intake Manifold751
Catalytic Converter751
Exhaust Heat Shields751
Exhaust System 2.5 Liter Engine752
Exhaust System 4.0 Liter Engine752
Exhaust Pipe753
Muffler Tailpipe Assembly754
Intake Manifold-2 .51- Engine754
Frame And Bumpers759
Front Tow Hook759
Front Tow Eye759
Front Bumper Extension759
Front Bumper760
Rear Tow Eye760
Rear Bumper Extension760
Rear Bumper760
Frame762
Body Holddowns762
Frame Service763
Frame Straightening763
Frame Repairs763
Drilling Holes763
Frame Fasteners764
Transfer Case Skid Plate764
Energy Management Holes764
Transmission Mount-Manual Transmission764
Fuel Tank Skid Plate765
Windshield Opening765
Door Opening766
Quarter Window Opening767
Engine Compartment768
Tailgate And Liftgate Opening769
Fuel System773
Fuel Requirements773
Gasoline/Oxygenate Blends773
Reformulated Gasoline774
Materials Added To Fuel774
Fuel Delivery System775
Fuel Pump Module775
Fuel Pump775
Fuel Gauge Sending Unit776
Fuel Filter/Fuel Pressure Regulator776
Fuel Pump Module Components776
Fuel Injectors777
Fuel Rail777
Quick-Connect Fittings777
Fuel Pump Pressure Test-2 .5L Engine777
Fuel Pump Pressure Test-4 .01- Engine778
Fuel Injector Test779
Fuel System Pressure Release Procedure-Without Test Port779
Fuel System Pressure Release Procedure-With Test Port779
Uel Tubes/Lines/Hoses And Clamps780
Two-Tab Type Fitting780
Fuel Line At Fuel Rail781
Disconnection/Connection At Fuel Rail781
Fuel Pump Inlet Filter783
Fuel Injection System789
Ignition Switch (Key-On) Mode790
Engine Startup Mode790
Engine Warm-Up Mode791
Idle Mode791
Cruise Mode791
Acceleration Mode791
Deceleration Mode792
Wide Open Throttle Mode792
Ignition Switch Off Mode792
Air Conditioning (A/C) Controls-Pcm Input793
Automatic Shutdown (Asd) Relay Sense-Pcm Input793
Battery Temperature Sensor-Pcm Input794
Battery Voltage-Pcm Input794
Five Volt Sensor Supply-Primary794
Brake Switch-Pcm Input794
Oxygen Sensor (02S)-Pcm Input795
Upstream Heated Oxygen Sensor795
Downstream Heated Oxygen Sensor795
Ignition Circuit Sense-Pcm Input796
Manifold Absolute Pressure (Map) Sensor796
Vehicle Speed And Distance Sensor-Pcm Input796
Power Steering Pressure Switch797
Power Ground797
Air Conditioning (A/C) Clutch Relay797
Steering813
Power Steering813
Steering System813
Power Steering System Diagnosis Charts814
Insufficient Assist Or Poor Return To Center815
Loose Steering And Vehicle Lead815
Power Steering Pump816
Power Steering Pump Pressure Test816
Pump Pressure Test816
Power Steering Pump-Initial Operation817
Pressure Test Gauge817
Pump Remote Reservoir-2.5L818
Tc-Series Pump Pulley819
Tc-Series Pump Reservoir819
Flow Control Valve820
Power Steering Gear821
Power Steering Gear Leakage Diagnosis822
Pitman Shaft Seals-In Vehicle822
Pitman Shaft823
Housing End Plug823
Adjuster Plug Assembly824
Spool Valve825
Manual Steering Gear833
Manual Steering System834
Pitman Shaft Seal835
Pitman Shaft And Cover835
Worm Shaft And Ball Nut836
Worm Bearing Adjuster838
Worm Bearing Preload839
Over-Center Preload839
Steering Column841
Steering Linkage843
Tie Rod843
Pitman Arm844
Steering Dampener844
Drag Link844
Body847
General Service Information847
Safety Precautions And Warnings847
Paint848
Paint Code848
Base Coat/Clear Coat Finish848
Finesse Sanding, Buffing, And Polishing848
Aftermarket Paint Repair Products849
Exterior Color849
Hard Top849
Interior Color849
Hard Top Repair850
Hard Top Hole Repair850
Fracture Repair850
Stationary Glass851
Seats854
Bucket Seatback854
Bucket Seatback Cover855
Recliner Release Cable855
Seat Back Cover855
Rear Hog Rings855
Rear Seatback856
Rear Seatback Cover856
Rear Seat Components856
Rear Seat Cushion Cover857
Hook And Loop Fasteners857
Body Component Service858
Body Lubrication859
Radiator Grille Panel859
Hood860
Grille Bumpers860
Hood Components860
Hood Insulation Panel861
Hood Hinge861
Hood Safety Latch861
Cowl Weatherstrip861
Cowl Grille And Screen862
Windshield Frame862
Windshield Frame Weatherstrip862
Upper Frame Weatherstrip Removal862
Lower Frame Weatherstrip Removal863
Lower Frame Weatherstrip Installation863
Windshield Hinge863
Body Decals864
Side View Mirror865
Fender Flare865
Front Fender865
Right Fender Installation866
Body Side Molding866
Left Fender Removal867
Left Fender Installation867
Side Step867
Full Door Trim Panel868
Full Door Hinge868
Full Door Outside Release Handle869
Grab Handle Support Bracket869
Full Door Lock Cylinder870
Full Door Latch870
Latch Rods870
Outside Door Handle Removal870
Full Door Latch Striker871
Full Door Inside Handle Actuator871
Inside Handle Actuator871
Full Door Glass872
Full Door Inner Belt Weatherstrip872
Full Door Outer Belt Seal872
Full Door Glass Run Channel Weatherstrip873
Full Door Weatherstrip873
Full Door Window Regulator874
Half Door Trim Panel874
Half Door874
Half Door Hinge874
Half Door Outside Handle875
Half Door Lock Cylinder875
Half Door Latch875
Half Door Latch Striker876
Half Door Inside Handle Actuator876
Half Door Weatherstrip876
Half Door Window877
Half Window877
Hard Top Latch877
Hard Top Air Exhauster878
Soft Top878
Soft Top Fabric879
Hard/Soft Top Latch879
Door Opening Frame880
Front Shoulder/Lap Belt And Buckle880
Front Shoulder/Lap Belt And Retractor Removal880
Front Shoulder/Lap Belt And Retractor Installation880
Rear Shoulder/Lap Belt And Buckle881
Seat/Lap Belt And Retractor Removal881
Seat/Lap Belt And Retractor Installation881
Rear Buckle Removal882
Rear Buckle Installation882
Bucket Seat882
Mini Floor Console882
Full Floor Console883
Console Lock Cylinder883
Shift Boot884
Rear Seat884
Add-A-Trunk885
Front Carpet885
Center Carpet885
Cargo Area Carpet885
Sport Bar886
Vehicle Carpet886
A-Pillar Weatherstrip887
Rear View Mirror888
Rearview Mirror Support Bracket888
Sunvisor888
Wheelhouse Splash Shield889
Liftgate Glass Support Cylinder889
Liftgate Glass889
Liftgate Glass Hinge890
Liftgate Glass Weatherstrip890
Spare Tire Carrier890
License Plate Bracket891
Tailgate891
Tailgate Hinge892
Tailgate Outside Handle892
Tailgate Lock Cylinder892
Tailgate Latch892
Tailgate Latch Striker893
Tailgate Weatherstrip And Channel893
Hood Adjustment894
Door Adjustment894
Tailgate Adjustment894
Body Lubricants895
Tires And Wheels897
Tire Information897
Tire Identification897
Tire Chains897
Radial-Ply Tires898
Spare Tire–Temporary898
Tire Inflation Pressures898
Over Inflation Wear898
Tire Pressure For High Speed Operation899
Replacement Tires899
Pressure Gauges899
Tread Wear Indicators899
Tire Noise Or Vibration900
Rotation900
Match Mounting900
Tire Rotation Pattern900
Repairing Leaks901
First Measurement On Tire901
Cleaning Tires902
Wheels903
Wheel Inspection903
Tire And Wheel Runout903
Wheel Installation904
Checking Tire/Wheel/Hub Runout904
Radial Runout904
Lateral Runout904
Wheel Replacement905
Tire And Wheel Balance905
Lug Nut Tightening Pattern905
Static Unbalance & Balance905
Dynamic Unbalance & Balance906
Transmission And Transfer Case907
Ax5 Manual Transmission907
Transmission Identification907
Gear Ratios908
Recommended Lubricant908
Transmission Assembly Information908
Low Lubricant Level908
Hard Shifting909
Fill Plug Location909
Geartrain Components909
Transmission Noise910
Marking Propeller Shaft And Axle Yokes910
Crankshaft Position Sensor—2.5L Engine910
Crankshaft Position Sensor —4.0L Engine911
Removing/Installing Shift Lever911
Front Bearing Retainer Seal912
Align Propeller Shaft And Rear Axle Yokes Alignment Marks912
Install Front Bearing Retainer Seal912
Extension Housing Seal913
Adapter Housing Seal913
Adapter/Extension Housing And Front Bearing Retainer914
Remove Shift Tower914
Remove Shift Tower Gasket914
Remove Detent Ball Plug914
Remove Detent Spring915
Remove Detent Ball915
Shift Arm Retainer Bolt Removal915
Shift Arm Rstrictor Pins915
Loosen Adapter/Extension Housing916
Remove Adapter/Extension Housing–Typical916
Speedometer Drive Gear Assembly916
Remove Front Bearing Retainer916
Separate Intermediate Plate And Transmission Case917
Remove Intermediate Plate From Transmission Case917
Apply Sealer To Transmission Gear Case917
Install Front Bearing Snap-Rings917
Install Front Bearing Retainer918
Install Adapter/Extension Housing–Typical918
Position Shift Arm In Adapter Or Extension Housing918
Install Shifter Arm Shaft919
Install Shift Arm Retainer Bolt919
Shifter Arm Shaft Plug Installation919
Install Shifter Restrictor Pins919
Install Detent Spring920
Install Detent Ball Plug920
Install Shift Tower920
Install Backup Lamp Switch920
Shift Mechanism And Geartrain921
Positioning Intermediate Plate In Vise921
Remove Fifth Gear Snap-Ring921
Remove Shift Fork Retainer Bolt921
Remove Fifth Gear Synchro Ring922
Remove Fifth Gear And Synchro Assembly922
Remove Fifth Gear Thrust Ring922
Remove Fifth Gear Thrust Ring Lock Ball922
Remove Output Shaft Rear Bearing Retainer923
Remove Shift Fork To Shift Rail Bolts923
Remove Reverse Shift Arm Bracket Bolts923
Remove Output Shaft Rear Bearing Snap-Ring923
Remove Countershaft And Countershaft Rear Bearing924
Remove Mainshaft924
Remove 3–4 Shift Fork924
Remove 1–2 Shift Fork924
Remove Lock Ball And Spring925
Remove Fifth Gear Shift Rail925
Remove Fifth Gear Check Ball925
Remove Reverse Shift Head And Rail Assembly925
Remove Interlock Pin From Reverse Shift Rail926
Remove Reverse Check Ball926
Remove 1–2 Shift Rail Interlock Pin926
Remove 1–2 Check Ball926
Shift Rail Components927
Install 1–2 Check Ball927
Install 1–2 Shift Rail Interlock Pin927
Install Reverse Check Ball928
Install Reverse Interlock Pin928
Install Reverse Arm Bracket To Fork928
Install Reverse Shift Rail928
Install Fifth Gear Check Ball929
Install Fifth Gear Shift Rail929
Install 1–2 Shift Fork929
Install 3–4 Shift Fork929
Install Shift Fork Bolts930
Reverse Shift Arm Position930
Install Compression Spring And Pin930
Install Reverse Idler Shaft930
Align Idler Shaft Pin931
Depress Pin In Reverse Idler Gear Shaft931
Install Fifth Gear Thrust Ring Lock Ball931
Install Fifth Gear Thrust Ring931
Countershaft932
Input Shaft932
Install Fifth Gear Retainer Bolt932
Countershaft Front Bearing Snap-Ring932
Input Shaft Components933
Select Input Shaft Bearing Snap-Ring933
Output Shaft934
Install Output Shaft Pilot Bearing Rollers934
Check Output Shaft Gear Thrust Clearance934
Remove First Gear Bearing Inner Race Lock Ball935
Remove 3–4 Synchronizer Snap Ring935
Remove 3–4 Synchronizer And Third Gear935
Synchronizer Identification936
Select 3–4 Synchronizer Snap-Ring936
Check Third Gear Clearance936
Install First Gear Bearing Inner Race Lock Ball937
First Gear Components937
Check First–Second Gear Thrust Clearance937
Semi-Synchronized Reverse Idler Gear938
Remove Reverse Idler Gear Snap-Ring938
Remove Reverse Idler Gear Plate Washer938
Select/Install Fifth Gear Snap Ring938
Ax5 Manual Transmission Components939
Remove Reverse Idler Gear Synchronizer Ring939
Gear Case, Adapter/Extension Housing, Intermediate Plate939
Gear And Synchronizer940
Check Output Shaft Runout940
Check Gear–To–Race Clearance940
Components940
Check Synchronizer Ring Wear941
Check Fork–To–Hub Clearance941
Ax5942
Ax15 Manual Transmission944
Transmission Gear Ratio944
Install Reverse Shift Rail Interlock Pin966
Install Shift Forks966
Install 1–2 Shift Rail Interlock Plug967
Install 1–2 Shift Rail967
Install 3–4 Shift Rail Interlock Plug967
Install Shift Fork To Shift Rail Bolts968
Install Shift Rail C-Rings968
Install Reverse Idler Gear And Shaft968
Install Output Shaft Rear Bearing Retainer968
Install Countershaft Fifth Gear Bearings969
Install Countershaft Fifth Gear Assembly969
Install Fifth Gear Snap-Ring970
Install Reverse Shift Head And Rail Assembly970
Install Fifth Gear Shift Fork970
Install Fifth Gear Shift Fork Retainer Bolt970
Install Detent Balls And Springs971
Separate Input And Output Shafts971
Reverse Idler Gear Bushing979
Automatic Transmission—30/32Rh981
Diagnosis Chart993
Fluid Level Check1000
Fluid Level Check Procedure1000
Fluid And Filter Replacement1000
Transmission Fill Procedure1001
Converter Drainback Check Valve Service1001
Oil Cooler Flow Check1002
Flushing Coolers And Tubes1002
Cooler Flush Using Tool 69061002
Aluminum Thread Repair1003
Crankshaft Position Sensor—4.0L Engine1003
Typical Method Of Checking Converter Seating1004
Rear Clutch1038
Clutch Piston Spring Installation1038
Correct Spring Retainer Installed Position1038
Measuring Front Clutch Pack Clearance1038
Rear Clutch Components1039
Removing/Installing Input Shaft Snap-Ring1039
Rear Clutch Retainer And Input Shaft Seal Ring Installation1040
Input Shaft Seal Ring Identification1040
Pressing Input Shaft Into Rear Clutch Retainer1040
Piston Spring/Wave Spring Position1040
Planetary Geartrain/Output Shaft1041
Valve Body Components1048
Overrunning Clutch/Low-Reverse Drum/Overdrive Piston Retainer1049
Front Servo1049
Rear Servo1050
Oil Pump And Reaction Shaft Support1050
Front Clutch1050
Rear Servo Components1050
Gearshift Cable1051
Gearshift Adjustment Procedure1051
Retainer Bushing Location/Inspection1051
Brake Transmission Shift Interlock Cable Adjustment1052
Transmission Throttle Valve Cable Adjustment1052
Park Lock Cable Attachment1052
Checking Throttle Valve Cable Adjustment1052
Front Band Adjustment1053
Throttle Cable Attachment At Engine1053
Throttle Cable Attachment At Transmission1053
Front Band Adjustment Screw Location1053
Rear Band Adjustment1054
Valve Body1054
Control Pressure Adjustments1054
Line Pressure Adjustment1054
Throttle Pressure Adjustment1055
Schematics And Diagrams1056
Hydraulic Schematics1056
Nv231 Transfer Case1074
Operating Ranges1074
Transfer Case Identification1074
Recommended Lubricant And Fill Level1074
Nv231 Diagnosis1075
Transfer Case1076
Shift Lever1076
Transfer Case Mounting1076
Shift Linkage1077
Speedometer Components1077
Front Output Shaft Seal1078
Rear Retainer And Oil Pump Removal1078
Heating And Air Conditioning1101
Heater And Air Conditioner Controls1102
Service Warnings And Precautions1102
Cooling System Requirements1103
Coolant Precautions1103
Refrigerant Hoses/Lines/Tudes Precautions1103
Description And Operation Accumulator1104
Blower Motor Resistor1105
Blower Motor Switch1105
Compressor Clutch Relay1105
Condenser1106
Fixed Orifice Tube1106
Heater Core1106
High Pressure Cut-Off Switch1106
Evaporator Coil1106
High Pressure Relief Valve1106
High Speed Blower Motor Relay1106
Low Pressure Cycling Clutch Switch1107
Refrigerant Line Couplers1107
Refrigerant System Service Equipment1107
Refrigerant System Service Ports1108
Vacuum Check Valve1108
Vacuum Reservoir1108
Diagnosis And Testing A/C Performance1108
Performance Temperature And Pressure Chart1109
Pressure Diagnosis1110
Heater Performance1111
Maximum Heater Output1111
Obstructed Coolant Flow1111
Mechanical Problems1111
Vacuum System1111
Heater-A/C Controls1112
Locating Vacuum Leaks1112
Compressor Clutch Coil1116
Compressor1116
Refrigerant System Leaks1118
Refrigerant Oil Level1119
Refrigerant Recovery1119
Refrigerant System Charge1119
Refrigerant System Evacuate1119
Compressor Clutch1121
Accumulator1126
Heater-A/C Control1127
Temperature Control Cable1128
Mode Door Vacuum Actuators1130
Heater-A/C Housing1131
Heater-A/C Housing Doors1132
Ducts And Outlets1134
Index1135