2003 Jeep Wrangler TJ Parts Catalog Manual – PDF DOWNLOAD
DESCRIPTION:
2003 Jeep Wrangler TJ Parts Catalog Manual – PDF DOWNLOAD
PAGE NUMBERING :
Two-part page numbers are used throughout this catalog. The first part of the page designatioп indicates one major group or sectюn. The second part indicates the actual page number in the group. For example·
2-1 indicates Group 2, Front Suspension, Page 1
3-4 ind1cates Group 3, Axle Rear, Page 4
In the maintenance of the Loose Leaf Parts Catalog Revisюn Service, it may become necessary to add information beyond the capac1ty of the page. In this event, ап “А” page will Ье used F or example, if it becomes necessary, because of change, to add several part numbers to page 2-1 and space does not perm1t the add1tion, you w1ll Ье given Page 2-lA Page 2-lA should Ье filed immediately followшg Page 2-1.
Figure and Item Numbers are also commonly used to 1dent1fy locatюns m the Catalog, ie , 14-910/8 refers to Group 14, illustratюn 910, Item Numbeг 8. Illustratюп Numbers are always ascendшg sequeпtial
w1thin the Groups
SYМBOLS USED IN THIS CATALOG
The Following symbols are commonly used with Part Number and Quant1ty tnformatюn m this Catalog·
AR – Ind1cates the quantity reqшred may vary or 1s to Ье determined Ьу the user
PAR – Indicates ”Part As Reqшred”
BLANК – Indicates ”All Cond1tion
– = ”Not Illustrated”
LOGICAL ILLUSTRATIONS
Refer to Шustration in front of each group. Тhis will give ass1stance to as how each group 1s broken down and what Spec1fi.c Шustration should Ье referenced
ILLUSTRATION NUМВERING INDEX
Illustration numbers in this Catalog are Group standards. Тhis indicates group and consistent content. ЕХАМРLЕ 8-100 1s а Logical Шustratlon for Starters 8-101 to 8-199 are Specific Шustrations used for Starters for all Catalogs 8-200 will contain Alternators for а11 Catalogs and so 011. Always refer to group index iп froпt of each gгoup.
TABLE OF CONTENTS:
2003 Jeep Wrangler TJ Parts Catalog Manual – PDF DOWNLOAD
2003TJ......................................................................................... 1 Return To Model Year Index................................................................. 0 Return To 2003 Vehicle Family Index........................................................ 0 General Information........................................................................ 1 Abbreviations.......................................................................... 7 Alphabetic Index....................................................................... 6 Body Code Plate Interpretation......................................................... 7 Catalog Groups - Titles & Contents..................................................... 2 How to Use This Catalog and Locate Parts............................................... 5 Illustration Index..................................................................... 6 Illustration Numbering Index........................................................... 5 Index.................................................................................. 1 Logical Illustration Index............................................................. 2 Logical Illustrations.................................................................. 5 Numerical Index........................................................................ 6 Page Numbering......................................................................... 5 Part Packages.......................................................................... 6 Standard Parts......................................................................... 6 Symbols Used in this Catalog........................................................... 5 GROUP 001 Component Parts for Mopar Accessories.......................................... 8 FIGURE 001-110 -->Player Kit - CD - Changher - 6 Disc.................................. 10 FIGURE 001-220 -->Bike Carrier - Hitch Mount 2 Bikes................................... 11 FIGURE 001-222 -->Bike Carrier - Spare Tire Mount...................................... 12 FIGURE 001-232 -->Ski Carrier - Spare Tire Mount....................................... 13 FIGURE 001-250 -->Trailer Tow - Receiver Kit........................................... 14 FIGURE 001-310 -->Speed Control Kit.................................................... 15 FIGURE 001-320 -->Top Kit - Soft Hardtop Replacement................................... 16 FIGURE 001-410 -->Bumper Kit- Front Tubular............................................ 17 FIGURE 001-420 -->Bumper Kit - Rear Tubular............................................ 18 FIGURE 001-430 -->Extension Kit - Bumper Front......................................... 19 FIGURE 001-440 -->Side Step Kit........................................................ 20 FIGURE 001-510 -->Shield Kit - Air Front............................................... 21 FIGURE 001-550 -->Hardtop Wiring Kit................................................... 22 FIGURE 001-610 -->Light Kit - Fog...................................................... 23 FIGURE 001-620 -->Light Kit - Off Road................................................. 24 FIGURE 001-630 -->Bar Kit - Light Windshield........................................... 25 FIGURE 001-640 -->Installation Package - Lights Off Road............................... 26 FIGURE 001-650 -->Heater Kit - Engine Block............................................ 27 FIGURE 001-710 -->Tomb Raider Edition.................................................. 28 FIGURE 001-820 -->Console Kit - Floor.................................................. 29 FIGURE 001-910 -->Alarm - EVS Base System.............................................. 30 GROUP 002 Front Suspension & Drive....................................................... 31 FIGURE 002-110 -->Suspension, Front Spring with Control Arms and Track Bar............. 32 FIGURE 002-120 -->Bar, Front Sway...................................................... 34 FIGURE 002-210 -->Shafts, Front Axle................................................... 35 FIGURE 002-310 -->Housing,Front Axle,4 Wheel Drive..................................... 36 FIGURE 002-410 -->Axle Assembly,Front,4 Wheel Drive.................................... 38 FIGURE 002-610 -->Differential,Front Axle,Without [DSE]................................ 39 FIGURE 002-620 -->Differential,Front Axle,With [DSE]................................... 44 GROUP 003 Rear Axle...................................................................... 46 FIGURE 003-110 -->Axle Assembly, Rear.................................................. 47 FIGURE 003-210 -->Housing,Rear Axle,Dana M35/194MM [DRJ]............................... 48 FIGURE 003-220 -->Housing,Rear Axle,Dana 44/226MM [DRK]................................ 49 FIGURE 003-230 -->Differential,With and Without Trac-Lok [DSA] Dana M35/194MM [DRJ].... 51 FIGURE 003-240 -->Differential,With and Without Trac-Lok [DSA] Dana 44/226MM [DRK]..... 53 FIGURE 003-250 -->Differential,With Trulok Differential [DSE] Dana 44/226MM [DRK]...... 55 FIGURE 003-410 -->Shaft,Rear Axle,Dana 35/194MM [DRJ].................................. 56 FIGURE 003-420 -->Shaft,Rear Axle,Dana 44/226MM [DRK].................................. 57 GROUP 004 Parking Brake.................................................................. 58 FIGURE 004-110 -->Parking Brake Lever and Cables....................................... 59 FIGURE 004-120 -->Parking Brake Assembly,Rear,Disc..................................... 60 GROUP 005 Service Brakes................................................................. 61 FIGURE 005-110 -->Front Brakes......................................................... 62 FIGURE 005-210 -->Brakes,Rear,Disc..................................................... 64 FIGURE 005-220 -->Brakes,Rear,Drum..................................................... 65 FIGURE 005-310 -->Power Brake Booster.................................................. 68 FIGURE 005-410 -->Master Cylinder...................................................... 69 FIGURE 005-510 -->Hydraulic Control Unit,Anti-lock..................................... 70 FIGURE 005-520 -->Brake Lines and Hoses,Front,LHD and Rear,LHD,RHD,without ABS......... 71 FIGURE 005-530 -->Brake Lines and Hoses,Front,RHD,without ABS.......................... 73 FIGURE 005-540 -->Brake Lines and Hoses Front,LHD,with ABS............................. 74 FIGURE 005-550 -->Brake Lines and Hoses Rear,LHD,with ABS.............................. 76 FIGURE 005-610 -->Brake Pedal,LHD...................................................... 77 FIGURE 005-620 -->Brake Pedal,RHD...................................................... 78 GROUP 006 Clutch......................................................................... 79 FIGURE 006-110 -->Clutch............................................................... 80 FIGURE 006-210 -->Housing & Pan, Clutch................................................ 81 FIGURE 006-310 -->Control, Clutch...................................................... 82 FIGURE 006-410 -->Pedal, Clutch........................................................ 83 GROUP 007 Cooling........................................................................ 84 FIGURE 007-110 -->Radiator And Related Parts........................................... 85 FIGURE 007-202 -->Water Pump, 2.4L Engine.............................................. 87 FIGURE 007-205 -->Water Pump, 4.0L Engine.............................................. 88 FIGURE 007-310 -->Tank, Coolant Recovery............................................... 89 FIGURE 007-402 -->Drive Pulleys, 2.4L Engine........................................... 90 FIGURE 007-405 -->Drive Pulleys, 4.0L Engine........................................... 91 FIGURE 007-510 -->Drive Belts, 2.4L Engine............................................. 92 FIGURE 007-515 -->Drive Belts, 4.0L Engine............................................. 93 FIGURE 007-610 -->Oil Cooler Lines, 2.4L Engine........................................ 94 FIGURE 007-620 -->Oil Cooler Lines, 4.0L Engine........................................ 95 FIGURE 007-705 -->Grille And Related Parts............................................. 96 GROUP 008 Electrical..................................................................... 97 FIGURE 008-105 -->Starter.............................................................. 99 FIGURE 008-205 -->Alternator 2.4L Engine...............................................100 FIGURE 008-210 -->Alternator 4.0L Engine...............................................101 FIGURE 008-405 -->Modules..............................................................102 FIGURE 008-505 -->Power Distribution Center Relays and Fuses...........................103 FIGURE 008-510 -->Fuse Block...........................................................104 FIGURE 008-605 -->Sensors Engine 2.4L Engine [ED0].....................................105 FIGURE 008-610 -->Sensors Engine 4.0L [ER0]............................................106 FIGURE 008-615 -->Sensors - Body.......................................................108 FIGURE 008-620 -->Sensors Drive Train..................................................109 FIGURE 008-705 -->Single Board Engine Controllers (JTEC Module)........................110 FIGURE 008-805 -->Switches - Instrument Panel..........................................111 FIGURE 008-810 -->Switches Drivetrain..................................................113 FIGURE 008-815 -->Switches - Body......................................................114 FIGURE 008-905 -->Horns................................................................115 FIGURE 008-1005-->Battery Tray & Cables................................................116 FIGURE 008-1105-->Lamps--Front.........................................................117 FIGURE 008-1110-->Lamps--Rear..........................................................120 FIGURE 008-1115-->Lamps--Cargo-Dome-Courtesy...........................................121 FIGURE 008-1120-->Bulbs & Sockets......................................................122 FIGURE 008-1205-->Wiring--Engine & Related Parts.......................................123 FIGURE 008-1305-->Wiring--Headlamp / Dash Panel........................................125 FIGURE 008-1405-->Wiring Instrument Panel & Fuses......................................127 FIGURE 008-1505-->Wiring--Body & Accessory.............................................128 FIGURE 008-1605-->Wiring Repair Packages...............................................130 FIGURE 008-1610-->Power Distribution Center Repair.....................................131 FIGURE 008-1905-->Spark Plugs--Cables--Coil............................................132 GROUP 08A Instrument Panel and Radios and Consoles.......................................133 FIGURE 08A-110 -->Instrument Panel.....................................................134 FIGURE 08A-210 -->Instrument Cluster...................................................138 FIGURE 08A-315 -->Radio................................................................139 FIGURE 08A-320 -->Antenna..............................................................140 FIGURE 08A-325 -->Speakers.............................................................141 FIGURE 08A-410 -->Consoles Full & Mini.................................................142 GROUP 009 Engine Mounting................................................................144 FIGURE 009-110 -->Engine Mounting, Front, 2.4 (ED1) 4.0 (ERO)..........................145 FIGURE 009-120 -->Engine Mounting, Rear, 2.4 (ED1) 4.0 (ERO)...........................146 GROUP 2.4L Engine 2.4L Four Cylinder.....................................................147 FIGURE 2.4L-210 -->Cylinder Head, 2.4L [ED1]...........................................148 FIGURE 2.4L-310 -->Cylinder Block, 2.4L [ED1]..........................................149 FIGURE 2.4L-410 -->Crankshaft, Pistons and Flywheel, 2.4L [ED1]........................150 FIGURE 2.4L-510 -->Camshaft and Valves 2.4L [ED1]......................................151 FIGURE 2.4L-610 -->Timing Belt and Cover, 2.4L [ED1]...................................152 FIGURE 2.4L-620 -->Balance Shafts, 2.4L [ED1]..........................................153 FIGURE 2.4L-710 -->Engine Oiling, 2.4L [ED1]...........................................154 FIGURE 2.4L-810 -->Intake and Exhaust Manifolds, 2.4L [ED1]............................155 FIGURE 2.4L-910 -->Crankcase Ventilation, 2.4L [ED1]...................................156 GROUP 4.0L Engine 4.0L Six Cylinder......................................................157 FIGURE 4.0L-210 -->Cylinder Head, 4.0 (ERH)............................................158 FIGURE 4.0L-310 -->Cylinder Block, 4.0 (ERH)...........................................159 FIGURE 4.0L-410 -->Crankshaft, Piston and Torque Converter, 4.0 (ERH)..................160 FIGURE 4.0L-510 -->Camshaft and Valves, 4.0 (ERH)......................................162 FIGURE 4.0L-610 -->Timing Cover, 4.0 (ERH).............................................163 FIGURE 4.0L-710 -->Engine Oiling, 4.0 (ERH)............................................164 FIGURE 4.0L-810 -->Manifold, Intake and Exhaust........................................165 FIGURE 4.0L-910 -->Crankcase Ventilation, 4.0 (ERH)....................................166 GROUP 011 Exhaust........................................................................167 FIGURE 011-110 -->Exhaust System, 2.4 (ED1), 4.0 (ERO).................................168 FIGURE 011-210 -->Heat Shields, 2.4 (ED1), 4.0 (ERH)...................................169 GROUP 013 Frames and Bumpers.............................................................170 FIGURE 013-110 -->Frame................................................................171 FIGURE 013-210 -->Bumper, Front........................................................174 FIGURE 013-310 -->Bumper, Rear.........................................................176 FIGURE 013-510 -->Body Mounting Hardware...............................................177 GROUP 014 Fuel...........................................................................178 FIGURE 014-110 -->Fuel Tank, 2.4 (ED1), 4.0 (ERH)......................................180 FIGURE 014-210 -->Fuel Filler Tube, 2.4 (ED1), 4.0 (ERH)...............................181 FIGURE 014-310 -->Fuel Lines, Front,2.4 (ED1) 4.0 (ERH)................................182 FIGURE 014-320 -->Fuel Lines, Rear, Chassis 2.4L (ED1) 4.0 (ERH).......................183 FIGURE 014-410 -->Fuel Injection System, 2.4 (ED1), 4.0 (ERH)..........................184 FIGURE 014-510 -->Fuel Module, 2.4 (ED1), 4.0 (ERH)....................................185 FIGURE 014-610 -->Throttle Body, 2.4 (ED1), 4.0 (ERH)..................................186 FIGURE 014-710 -->Throttle Controls, 2.4 (ED1), 4.0 (ERH)..............................187 FIGURE 014-810 -->Air Cleaner, 2.4 (ED1), 4.0 (ERH)....................................188 FIGURE 014-1010-->Speed Control, 2.4 (ED1), 4.0 (ERH)..................................189 FIGURE 014-1110-->Accelerator Pedal, 2.4 (ED1), 4.0 (ERH)..............................190 GROUP 016 Propeller Shafts and U-Joints..................................................191 FIGURE 016-110 -->Propshaft,Front and Rear.............................................192 GROUP 017 Rear Suspension................................................................194 FIGURE 017-110 -->Suspension, Rear with Shocks,Springs and Track Bar..................195 FIGURE 017-210 -->Stabilzer, Rear......................................................197 GROUP 019 Steering.......................................................................198 FIGURE 019-110 -->Wheel, Steering......................................................199 FIGURE 019-210 -->Column, Steering Upper and Lower.....................................200 FIGURE 019-310 -->Gear, Power Steering.................................................202 FIGURE 019-410 -->Linkage and Damper...................................................203 FIGURE 019-510 -->Pump, Power Steering.................................................205 FIGURE 019-710 -->Hoses and Reservoir, 2.4L Engine [ED0]...............................206 FIGURE 019-720 -->Hoses and Reservoir,4.0L Engine [ER0]................................207 GROUP 42RLE Automatic Transaxle 4 Speed..................................................208 FIGURE 42RLE-110 -->Transaxle Assembly [DG6]...........................................209 FIGURE 42RLE-120 -->Mounting, Transmission [ED1 + DG6].................................210 FIGURE 42RLE-130 -->Mounting, Transmission [ERH + DG6].................................211 FIGURE 42RLE-210 -->Transmission Case [DG6]............................................212 FIGURE 42RLE-220 -->Adapter, Rear [DG6]................................................213 FIGURE 42RLE-310 -->Oil Pump & Reaction Shaft [DG6.....................................214 FIGURE 42RLE-410 -->Clutch, Input Shaft [DG6]..........................................216 FIGURE 42RLE-420 -->Gear Train [DG6]...................................................222 FIGURE 42RLE-710 -->Valve Body [DG6]...................................................230 FIGURE 42RLE-720 -->Accumulator Piston & Springs [DG6].................................233 FIGURE 42RLE-730 -->Parking Sprag [DG6]................................................234 FIGURE 42RLE-1210-->Gearshift Controls [DG6]...........................................235 GROUP 3550 Manual Transmission 5 Speed...................................................236 FIGURE 3550-110 -->Transmission (DDD).................................................237 FIGURE 3550-210 -->Case and Extension (DDD)...........................................238 FIGURE 3550-410 -->Gear Train (DDD)....................................................240 FIGURE 3550-910 -->Fork and Rails (DDD)................................................244 FIGURE 3550-1210-->Gearshift Controls (DDD)............................................246 GROUP NV2550 Manual Transmission 5 Speed.................................................247 FIGURE NV2550-110 -->Transmission [NV 2550] [DDK]......................................248 FIGURE NV2550-210 -->Case and Extension [NV 2550] [DDK]..............................249 FIGURE NV2550-410 -->Gear Train [NV 2550] [DDK].......................................251 FIGURE NV2550-910 -->Fork and Rail [NV 2550] [DDK]...................................253 FIGURE NV2550-1210-->Gearshift Controls................................................254 GROUP 231 Transfer Case Model 231........................................................255 FIGURE 231-110 -->Command Trac Transfer Case [DHN]....................................256 FIGURE 231-210 -->Case & Related Parts, Command Trac [DHN].............................257 FIGURE 231-410 -->Gear Train, Command Trac [DHN].......................................261 FIGURE 231-910 -->Forks & Rails, Command Trac [DHN]....................................265 FIGURE 231-1210-->Gearshift Controls, Command Trac [DHN]...............................267 GROUP 241 Transfer Case Model 241........................................................269 FIGURE 241-110 -->Transfer Case [DHW].................................................270 FIGURE 241-210 -->Case Transfer & Related Parts [DHW]..................................271 FIGURE 241-410 -->Gear Train [DHW]....................................................272 FIGURE 241-910 -->Forks [DHW].........................................................273 FIGURE 241-1210-->Controls [DHW].....................................................274 GROUP 21P Speedometer Pinions............................................................276 FIGURE 21P-110 -->Speedometer Pinion & Housing.........................................277 GROUP 022 Wheels, Covers and Jacks.......................................................278 FIGURE 022-110 -->Wheels...............................................................279 FIGURE 022-210 -->Caps And Covers......................................................280 FIGURE 022-310 -->Jack And Storage.....................................................281 FIGURE 022-410 -->Wheel, Spare Tailgate Mounted........................................282 GROUP 23D Wiper/Lock Cylinder and Keys...................................................283 FIGURE 23D-105 -->Lock Cylinders & Keys................................................284 FIGURE 23D-205 -->Wiper System Front...................................................286 FIGURE 23D-305 -->Rear Wiper System....................................................287 GROUP 024 Air Conditioning & Heater......................................................288 FIGURE 024-105 -->Hevac Unit, LHD......................................................289 FIGURE 024-110 -->Hevac Unit, RHD......................................................290 FIGURE 024-210 -->Hoses, Heater 2.4L Engine............................................291 FIGURE 024-220 -->Hoses, Heater 4.0L Engine............................................292 FIGURE 024-225 -->Plumbing, Hevac 2.4L Engine..........................................293 FIGURE 024-235 -->Plumbing, Hevac 4.0L Engine, LHD.....................................294 FIGURE 024-240 -->Pluming, Hevac 4.0L Engine, RHD......................................295 FIGURE 024-245 -->Seals, A/C Condenser.................................................296 FIGURE 024-310 -->Control, Heater And A/c..............................................297 FIGURE 024-410 -->Compressor, Air Conditioning.........................................298 FIGURE 024-610 -->Ducts, Heater And A/c................................................299 GROUP 025 Emission Systems...............................................................300 FIGURE 025-310 -->Vacuum Canister, 2.4 (ED1), 4.0 (ERH)................................301 FIGURE 025-410 -->Emission Control Vacuum Harness, 2.4 (EP1), 4.0 (ERH)................302 FIGURE 025-420 -->Leak Detection Pump, 2.4 (ED1), 4.0 (ERH)............................303 GROUP DTJ Doors and Related Parts........................................................304 FIGURE DTJ-110 -->Door, Full Front Shell And Hinges....................................305 FIGURE DTJ-120 -->Door, Full Front Glass And Regulator.................................306 FIGURE DTJ-130 -->Door, Full Front Lock And Controls...................................307 FIGURE DTJ-160 -->Door, Half Front Shell And Hinges....................................308 FIGURE DTJ-170 -->Door, Half Front Lock And Controls...................................309 FIGURE DTJ-510 -->Mirror, Exterior.....................................................310 FIGURE DTJ-610 -->Door Weatherstrips And Runs..........................................311 GROUP ETJ Exterior Ornamentation.........................................................312 FIGURE ETJ-210 -->Mouldings............................................................313 FIGURE ETJ-310 -->Decals...............................................................314 GROUP ITJ Interior Trim..................................................................315 FIGURE ITJ-110 -->Sunvisors............................................................316 FIGURE ITJ-210 -->Panels, Interior Trim, Front.........................................317 FIGURE ITJ-310 -->Carpets And Interior Trim Panels.....................................318 FIGURE ITJ-320 -->Floor Covering, Ruggedized...........................................320 FIGURE ITJ-410 -->Door Trim Panels Half Doors & Full Doors.............................321 FIGURE ITJ-510 -->Front Vinyl, Trim Code [H6]..........................................322 FIGURE ITJ-520 -->Front, Cloth, Trim Code [P5].........................................324 FIGURE ITJ-530 -->Front, Cloth, Trim Code [S5].........................................326 FIGURE ITJ-540 -->Front, Cloth, Trim Code [A5].........................................328 FIGURE ITJ-610 -->Rear, Vinyl, Trim Code [H6]..........................................329 FIGURE ITJ-620 -->Rear, Cloth, Trim Code [P5]..........................................331 FIGURE ITJ-630 -->Rear, Cloth, Trim Code [S5]..........................................333 FIGURE ITJ-640 -->Rear, Cloth, Trim Code [A5]..........................................334 FIGURE ITJ-710 -->Seat Belts...........................................................335 FIGURE ITJ-810 -->Seat Assemblies, Adjusters, Recliners................................337 GROUP STJ Body Sheet Metal Except Doors..................................................342 FIGURE STJ-210 -->Pan, Floor Front And Rear............................................344 FIGURE STJ-310 -->Plugs................................................................345 FIGURE STJ-410 -->Fender And Flare, Front..............................................346 FIGURE STJ-510 -->Hood, Lock, Catches..................................................347 FIGURE STJ-610 -->Panels, Cowl And Dash................................................348 FIGURE STJ-710 -->Glass, Windshield, Backlite, Quarter Windshield Frame, Hinges........349 FIGURE STJ-810 -->Panels, Body Side....................................................351 FIGURE STJ-1110-->Soft Top And Windows.................................................353 FIGURE STJ-1120-->Top Enclosure, Hard..................................................355 FIGURE STJ-1310-->Tailgate.............................................................356 FIGURE STJ-1320-->Add-a-Trunk..........................................................357 FIGURE STJ-1610-->Sport Bar Wrangler...................................................358 GROUP LBLS Labels All Vehicle Locations..................................................360 FIGURE LBLS-110 -->Instrument Panel, Visors and Trim...................................361 FIGURE LBLS-210 -->Engine Compartment..................................................362 FIGURE LBLS-310 -->Doors and Pillars...................................................363 FIGURE LBLS-410 -->Spare Tire..........................................................364 End of Catalog.............................................................................360
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