2003 jeep wrangler tj service repair manual
- 1. GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 0a Maintenance Schedules 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8N Power System 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission and Transfer Case 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Component and System Index Service Manual Comment Forms (Rear of Manual)
- 2. INTRODUCTION TABLE OF CONTENTS page page VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BODY CODE PLATE DESCRIPTION BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . 3 INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE . . . . . . . . 8 DESCRIPTION - THREADED HOLE REPAIR . . 8 METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 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. 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. 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. Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL - TYPICAL TJ INTRODUCTION 1
- 3. 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 A = Wrangler 4X4 (LHD) 4 = Wrangler 4X4 (RHD) 6 Series 2 = SE 3 = X 4 = Sport 5 = Sahara 7 Body Style 9 = Open Body 8 Engine P = 2.4L Gasoline S = 4.0L Gasoline 9 Check Digit 0 through 9 or X 10 Model Year 3=2003 11 Assembly Plant P = Toledo #2 12 thru 17 Vehicle Build Sequence 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 2 INTRODUCTION TJ VEHICLE IDENTIFICATION NUMBER (Continued)
- 4. BODY CODE PLATE DESCRIPTION BODY CODE PLATE A metal body code plate is attached to the floor pan under the drivers seat (Fig. 3). 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. 4). 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 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 23 - BODY/PAINT - SPECIFICATIONS) for color codes. DIGIT 9 Open Space Fig. 3 Body Code Plate Location 1 - SNAP 2 - REAR CARPET 3 - BODY CODE PLATE 4 - SNAP 5 - FLOOR PAN 6 - FRONT CARPET Fig. 4 Body Code Plate Decoding 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - ROOF 4 - CAR LINE SHELL 5 - ENGINE 6 - TRIM 7 - VIN 8 - MARKET 9 - TRANSMISSION 10 - PAINT PROCEDURE 11 - VEHICLE ORDER NUMBER TJ INTRODUCTION 3
- 5. 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 • ED1 = 2.4L 4 cyl. MPI Gasoline • ERH = 4.0L 6 cyl. MPI Gasoline BODY CODE PLATE—LINE 1 DIGITS 1, 2, AND 3 Transmission Codes • DDD = NV3550 5 - speed Manual • DDK = AX15 5 - speed Manual • DG6 = 42RLE 4 - speed Automatic DIGIT 4 Open Space DIGIT 5 Market Code • B = International DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) (Refer to VEHICLE DATA/VEHICLE INFORMA- TION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for breakdown of VIN code. INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart (Fig. 5) are used to identify various instrument con- trols. The symbols correspond to the controls and dis- plays that are located on the instrument panel. Fig. 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Warning 17 Engine Oil 6 Windshield Washer 18 Seat Belt 7 Windshield Wiper 19 Brake Failure 8 Windshield Wiper and Washer 20 Parking Brake 9 Windscreen Demisting and Defrosting 21 Front Hood 10 Ventilating Fan 22 Rear hood (Decklid) 11 Rear Window Defogger 23 Horn 12 Rear Window Wiper 24 Lighter 4 INTRODUCTION TJ BODY CODE PLATE (Continued)
- 6. FASTENER IDENTIFICATION DESCRIPTION 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 10.9. 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 (Fig. 6) and (Fig. 7). TJ INTRODUCTION 5
- 7. Fig. 6 FASTENER IDENTIFICATION 6 INTRODUCTION TJ FASTENER IDENTIFICATION (Continued)
- 8. Fig. 7 FASTENER STRENGTH TJ INTRODUCTION 7 FASTENER IDENTIFICATION (Continued)
- 9. FASTENER USAGE DESCRIPTION DESCRIPTION - FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Fasteners and torque specifications 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.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. DESCRIPTION - THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommen- dations for application and repair procedures. METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph Kilometers/ Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) 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 Refer to the Metric 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. 8). 8 INTRODUCTION TJ
- 10. Fig. 8 METRIC CONVERSION CHART TJ INTRODUCTION 9 METRIC SYSTEM (Continued)
- 11. TORQUE REFERENCES DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- tions Chart for torque references not listed in the indi- vidual torque charts (Fig. 9). Fig. 9 TORQUE SPECIFICATIONS 10 INTRODUCTION TJ
- 12. LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PARTS & LUBRICANT RECOMMENDATION DESCRIPTION DESCRIPTION - FLUID TYPES . . . . . . . . . . . . 1 DESCRIPTION - LUBRICANT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 2 FLUID TYPES DESCRIPTION DESCRIPTION - FUEL REQUIREMENTS . . . . . 3 DESCRIPTION - HOAT COOLANT . . . . . . . . . . 4 DESCRIPTION - ENGINE OIL . . . . . . . . . . . . . 5 DESCRIPTION - GEAR LUBRICATION RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DESCRIPTION - TRANSFER CASE - NV231 . . 5 DESCRIPTION - TRANSFER CASE - NV241 . . 5 DESCRIPTION - AXLE LUBRICATION . . . . . . . 6 DESCRIPTION - MANUAL TRANSMISSION . . . 6 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 6 DESCRIPTION - POWER STEERING FLUID . . 6 OPERATION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FLUID CAPACITIES SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 7 MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HOISTING STANDARD PROCEDURE - HOISTING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 14 TOWING STANDARD PROCEDURE - TOWING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 14 JUMP STARTING STANDARD PROCEDURE - JUMP STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 16 EMERGENCY TOW HOOKS DESCRIPTION — EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1). PARTS & LUBRICANT RECOMMENDATION DESCRIPTION DESCRIPTION - FLUID TYPES When service is required, DaimlerChrysler Corpo- ration recommends that only Mopart brand parts, lubricants and chemicals be used. Mopart provides the best engineered products for servicing DaimlerChrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used to service a Chrysler Corporation vehicle. • Society of Automotive Engineers (SAE) • American Petroleum Institute (API) (Fig. 2) • National Lubricating Grease Institute (NLGI) (Fig. 3) Fig. 1 INTERNATIONAL SYMBOLS TJ LUBRICATION & MAINTENANCE 0 - 1
- 13. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
- 14. SAE VISCOSITY RATING An SAE viscosity grade is used to specify the vis- cosity of engine oil. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Example SAE 5W-30 = multigrade engine oil. DaimlerChrysler Corporation only recommends multigrade engine oils. API QUALITY CLASSIFICATION This symbol (Fig. 2) on the front of an oil container means that the oil has been certified by the Ameri- can Petroleum Institute (API) to meet all the lubri- cation requirements specified by DaimlerChrysler Corporation. GEAR LUBRICANTS SAE ratings also apply to multigrade gear lubri- cants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W- 90. LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 3) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indi- cate the highest quality. SPECIALIZED LUBRICANTS AND OILS Some maintenance or repair procedures may require the use of specialized lubricants or oils. Con- sult the appropriate sections in this manual for the correct application of these lubricants. DESCRIPTION - LUBRICANT RECOMMENDATIONS Chassis Component Fluid, Lubricant, or Genuine Part Steering Gear & Linkage, Ball Joints, Prop Shafts & Yokes, Wheel Bearings MoparT Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Body Component Fluid, Lubricant, or Genuine Part Hinges: Door And Hood MoparT Engine Oil Liftgate MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Latches: Door, Hood/Safety Catch, Liftgate MoparT Multi-Purpose Lube NLG Grade 2 EP, GC-LB Seat Regulator & Track MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Window System Components MoparT Spray White Lube Lock Cylinders MoparT Lock Cylinder Lube Parking Brake Mechanism MoparT Wheel Brg. Grease NLGI Grade 1, GC-LBB Soft Top MoparT Soft Top Zipper Cleaner & Lubricant Fig. 2 API Symbol Fig. 3 NLGI Symbol 1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS 0 - 2 LUBRICATION & MAINTENANCE TJ PARTS & LUBRICANT RECOMMENDATION (Continued)
- 15. FLUID TYPES DESCRIPTION DESCRIPTION - FUEL REQUIREMENTS Your engine is designed to meet all emissions reg- ulations and provide excellent fuel economy and per- formance when using high quality unleaded “regular” gasoline having an octane rating of 87. The routine use of premium gasoline is not recommended. Under normal conditions the use of premium fuel will not provide a benefit over high quality regular gasolines and in some circumstances may result in poorer per- formance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage result- ing from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experi- ence these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We rec- ommend the use of gasolines that meet the WWFC specifications if they are available. REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as “reformulat- ed” gasoline. Reformulated gasoline contain oxygen- ates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly support the use of reformulated gaso- line. Properly blended reformulated gasoline will pro- vide excellent performance and durability for the engine and fuel system components. GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. CAUTION: DO NOT use gasoline containing METH- ANOL. Gasoline containing methanol may damage critical fuel system components. MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane num- ber without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasolines free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gaso- line retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline with- out MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California refor- mulated gasoline. SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning Cali- fornia reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satis- factorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle’s catalytic con- verter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a dif- ferent brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flash- ing, immediate service is required; see on-board diagnostics system section. MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions. FUEL SYSTEM CAUTIONS CAUTION: Follow these guidelines to maintain your vehicle’s performance: TJ LUBRICATION & MAINTENANCE 0 - 3
- 16. • The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine perfor- mance, damage the emission control system, and could result in loss of warranty coverage. • An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. • When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the tem- perature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. • The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle perfor- mance problems resulting from the use of such fuels or additives is not the responsibility of DaimlerChrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you. DESCRIPTION - HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWAL- LOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMIT- ING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equiva- lent ethylene-glycol base coolant with organic corro- sion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solu- tion. CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mix- tures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for pur- pose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the pres- ence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plas- tic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water-Is the recom- mended mixture, it provides protection against freez- ing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year- round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec- tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher per- 0 - 4 LUBRICATION & MAINTENANCE TJ FLUID TYPES (Continued)
- 17. centage of antifreeze can cause the engine to over- heat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyl- ene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. DESCRIPTION - ENGINE OIL WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERN- MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi- fied. MOPARt provides engine oils that conform to this service grade. SAE VISCOSITY An SAE viscosity grade is used to specify the vis- cosity of engine oil. Use only engine oils with multi- ple viscosities such as 5W-30 or 10W-30. These oils are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your par- ticular temperature range and variation. (Fig. 4) ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- SERVING is located on the label of an engine oil con- tainer. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 5). DESCRIPTION - GEAR LUBRICATION RATINGS SAE ratings also apply to multiple grade gear lubricants. In addition, API classification defines the lubricants usage. DESCRIPTION - TRANSFER CASE - NV231 Recommended lubricant for the NV231 transfer case is Mopart ATF +4, Automatic Transmission Fluid. DESCRIPTION - TRANSFER CASE - NV241 Recommended lubricant for the NV241 transfer case is Mopart ATF +4, Automatic Transmission Fluid. Fig. 4 Temperature/Engine Oil Viscosity Fig. 5 API Symbol TJ LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued)