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JEEP
SERVICE MANUAL
2003
WRANGLER
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Copyright © DaimlerChrysler Corporation
FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The
first page of the group has a contents section that lists major topics within the group.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values 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 as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
GROUP TAB LOCATOR
Introduction
0
0a
2
3
5
6
7
8A
8B
8E
8F
8G
8H
8I
8J
8L
8N
8O
8P
8Q
8R
8W
9
11
13
14
19
21
22
23
24
25
Lubrication & Maintenance
Maintenance Schedules
Suspension
Differential & Driveline
Brakes
Clutch
Cooling
Audio
Chime/Buzzer
Electronic Control Modules
Engine Systems
Heated Systems
Horn
Ignition Control
Instrument Cluster
Lamps
Power System
Restraints
Speed Control
Vehicle Theft Security
Wipers/Washers
Wiring
Engine
Exhaust System
Frame & Bumpers
Fuel System
Steering
Transmission and Transfer Case
Tires/Wheels
Body
Heating & Air Conditioning
Emissions Control
Component and System Index
Service Manual Comment Forms
(Rear of Manual)
TJ
INTRODUCTION
1
INTRODUCTION
TABLE OF CONTENTS
page
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
BODY CODE PLATE
DESCRIPTION
BODY CODE PLATE . . . . . . . . . . . . . . . . .
INTERNATIONAL SYMBOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .
page
FASTENER IDENTIFICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE . . . . . . . . 8
DESCRIPTION - THREADED HOLE REPAIR . . 8
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
...1
...1
...2
...3
...4
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:
•
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).
•
Type of vehicle.
•
Type of rear wheels.
•
Bar code.
•
Month, Day and Hour (MDH) of final assembly.
•
Paint and Trim codes.
•
Country of origin.
The label is located on the driver-side door shut-
face.
Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL -
TYPICAL
The Vehicle Identification Number is also
imprinted on the:
•
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 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
INTRODUCTION
TJ
VEHICLE IDENTIFICATION NUMBER (Continued)
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION
1
2
3
4
5
6
INTERPRETATION
Country of Origin
Make
Vehicle Type
Gross Vehicle Weight Rating
Vehicle Line
Series
CODE = DESCRIPTION
1 = United States
J = Jeep
4 = MPV
E = 3001-4000 lbs.
F = 4001-5000 lbs.
A = Wrangler 4X4 (LHD)
4 = Wrangler 4X4 (RHD)
2 = SE
3=X
4 = Sport
5 = Sahara
9 = Open Body
P = 2.4L Gasoline
S = 4.0L Gasoline
0 through 9 or X
3=2003
P = Toledo #2
Vehicle Build Sequence
7
8
9
10
11
12 thru 17
Body Style
Engine
Check Digit
Model Year
Assembly Plant
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:
•
Engine family and displacement
•
Evaporative family
•
Emission control system schematic
•
Certification application
•
Engine timing specifications (if adjustable)
•
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.
Fig. 2 VECI Label Location
1 - VECI LABEL

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