Jeep Wrangler Tj 1997 – 2006 Owner And Complete Official Factory Service Repair Full Workshop Manual
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Jeep Wrangler Tj 1997 – 2006 Owner And Complete Official Factory Service Repair Full Workshop Manual
FOREWORD:
The information contained in this service manual has been prepared for the professional automotive technician 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 components.
- 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.
TABLE OF CONTENTS:
Jeep Wrangler Tj 1997 – 2006 Owner And Complete Official Factory Service Repair Full Workshop Manual
10 INTRODUCTION 1
11 SYSTEM COVERAGE 1
12 SIX-STEP TROUBLE SHOOTING PROCEDURE 1
20 IDENTIFICATION OF SYSTEM 1
30 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 1
31 GENERAL DESCRIPTION1
32 FUNCTION OPERATION 1
321 FUEL CONTROL (GAS) 1
322 ON-BOARD DIAGNOSTICS 2
323 OTHER CONTROLS5
324 NON-MONITORED CIRCUITS10
325 SKIS OVERVIEW 10
326 SKIM ON-BOARD DIAGNOSTICS10
327 SKIS OPERATION 10
328 PROGRAMMING THE POWERTRAIN CONTROL MODULE 11
329 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE 11
3210 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY
IMMOBILIZER MODULE12
33 DIAGNOSTIC TROUBLE CODES 12
331 HARD CODE 12
332 INTERMITTENT CODE 12
333 STARTS SINCE SET COUNTER 13
334 NO START INFORMATION 13
34 USING THE DRBIIIT13
35 DRBIIIT ERROR MESSAGES AND BLANK SCREEN 13
351 DRBIIIT DOES NOT POWER UP 13
352 DISPLAY IS NOT VISIBLE 14
40 DISCLAIMERS, SAFETY, WARNINGS 14
41 DISCLAIMERS14
42 SAFETY 14
421 TECHNICIAN SAFETY INFORMATION14
422 VEHICLE PREPARATION FOR TESTING 14
423 SERVICING SUB-ASSEMBLIES 14
424 DRBIIIT SAFETY INFORMATION 14
43 WARNINGS AND CAUTIONS15
431 ROAD TEST WARNINGS15
432 VEHICLE DAMAGE CAUTIONS 15
50 REQUIRED TOOLS AND EQUIPMENT 15
60 ACRONYMS 15
70 DIAGNOSTIC INFORMATION AND PROCEDURES 19
COMMUNICATION
*NO RESPONSE FROM PCM (PCI BUS) 20
*NO RESPONSE FROM PCM (SCI ONLY) 21
*PCI BUS COMMUNICATION FAILURE 24
i
TABLE OF CONTENTS – Continued
DRIVEABILITY – GAS
INTERMITTENT CONDITION 26
P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW 27
P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH 27
P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW 27
P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH 27
P0051-O2 SENSOR 2/1 HEATER CIRCUIT LOW 27
P0052-O2 SENSOR 2/1 HEATER CIRCUIT HIGH 27
P0071-AMBIENT/BATTERY TEMP SENSOR PERFORMANCE 30
P0107-MAP SENSOR VOLTAGE TOO LOW 33
P0108-MAP SENSOR VOLTAGE TOO HIGH 35
P0111-INTAKE AIR TEMP PERFORMANCE 37
P0112-INTAKE AIR TEMP SENSOR VOLTAGE TOO LOW 39
P0113-INTAKE AIR TEMP SENSOR VOLTAGE TOO HIGH 41
P0117-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO LOW 43
P0118-ENGINE COOLANT TEMP SENSOR VOLTAGE TOO HIGH 45
P0121-TP SENSOR VOLTAGE DOES NOT AGREE WITH MAP SENSOR 47
P0122-THROTTLE POSITION SENSOR VOLTAGE TOO LOW 52
P0123-THROTTLE POSITION SENSOR VOLTAGE TOO HIGH 55
P0125-CLOSED LOOP TEMP NOT REACHED 58
P0131-O2 SENSOR 1/1 CIRCUIT VOLTAGE LOW60
P0137-O2 SENSOR 1/2 CIRCUIT VOLTAGE LOW60
P0151-O2 SENSOR 2/1 CIRCUIT VOLTAGE LOW60
P0157-O2 SENSOR 2/2 CIRCUIT VOLTAGE LOW60
P0132-O2 SENSOR 1/1 CIRCUIT VOLTAGE HIGH63
P0138-O2 SENSOR 1/2 CIRCUIT VOLTAGE HIGH63
P0152-O2 SENSOR 2/1 CIRCUIT VOLTAGE HIGH63
P0158-O2 SENSOR 2/2 CIRCUIT VOLTAGE HIGH63
P0133-O2 SENSOR 1/1 SLOW RESPONSE 66
P0139-O2 SENSOR 1/2 SLOW RESPONSE 66
P0153-O2 SENSOR 2/1 SLOW RESPONSE 66
P0159-O2 SENSOR 2/2 SLOW RESPONSE 66
P0135-O2 SENSOR 1/1 HEATER FAILURE 69
P0141-O2 SENSOR 1/2 HEATER FAILURE 69
P0155-O2 SENSOR 2/1 HEATER FAILURE 69
P0161-O2 SENSOR 2/2 HEATER FAILURE 69
P0136-O2 SENSOR 1/2 HEATER CIRCUIT MALFUNCTION72
P0171-1/1 FUEL SYSTEM LEAN 74
P0174-2/1 FUEL SYSTEM LEAN 74
P0172-1/1 FUEL SYSTEM RICH 79
P0175-2/1 FUEL SYSTEM RICH 79
P0201-INJECTOR #1 CONTROL CIRCUIT 84
P0202-INJECTOR #2 CONTROL CIRCUIT 84
P0203-INJECTOR #3 CONTROL CIRCUIT 84
P0204-INJECTOR #4 CONTROL CIRCUIT 84
P0205-INJECTOR #5 CONTROL CIRCUIT 84
P0206-INJECTOR #6 CONTROL CIRCUIT 84
P0300-MULTIPLE CYLINDER MIS-FIRE87
P0301-CYLINDER #1 MISFIRE87
P0302-CYLINDER #2 MISFIRE87
P0303-CYLINDER #3 MISFIRE87
P0304-CYLINDER #4 MISFIRE87
P0305-CYLINDER #5 MISFIRE87
ii
TABLE OF CONTENTS – Continued
P0306-CYLINDER #6 MISFIRE87
P0320-NO CRANK REFERENCE SIGNAL AT PCM 94
P0340-NO CAM REFERENCE SIGNAL AT PCM 98
P0351-IGNITION COIL # 1 PRIMARY CIRCUIT 102
P0352-IGNITION COIL # 2 PRIMARY CIRCUIT 102
P0353-IGNITION COIL # 3 PRIMARY CIRCUIT 102
P0420-1/1 CATALYTIC CONVERTER EFFICIENCY 105
P0432-2/1 CATALYTIC CONVERTER EFFICIENCY 105
P0441-EVAP PURGE FLOW MONITOR107
P0442-EVAP LEAK MONITOR MEDIUM (0040) LEAK DETECTED 109
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED 109
P0456-EVAP LEAK MONITOR SMALL (020) LEAK DETECTED109
P0443-EVAP PURGE SOLENOID CIRCUIT 112
P0460-FUEL LEVEL UNIT NO CHANGE OVER MILES 114
P0461-FUEL LEVEL UNIT NO CHANGE OVER TIME 114
P0462-FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW115
P0463-FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH 117
P0500-NO VEHICLE SPEED SIGNAL CIRCUIT 119
P0505-IDLE AIR CONTROL MOTOR CIRCUITS 122
P0523-OIL PRESSURE VOLTAGE TOO HIGH 124
P0551-POWER STEERING SWITCH FAILURE 126
P0601-PCM INTERNAL CONTROLLER FAILURE128
P0622-GENERATOR FIELD NOT SWITCHING PROPERLY 129
P0645-A/C CLUTCH RELAY CIRCUIT 131
P0700-EATX CONTROLLER DTC PRESENT 133
P1195-1/1 O2 SENSOR SLOW DURING CATALYST MONITOR134
P1196-2/1 O2 SENSOR SLOW DURING CATALYST MONITOR134
P1281-ENGINE IS COLD TOO LONG 136
P1282-FUEL PUMP/SYSTEM RELAY CONTROL CIRCUIT137
P1294-TARGET IDLE NOT REACHED 139
P1296-NO 5-VOLTS TO MAP SENSOR141
P1297-NO CHANGE IN MAP FROM START TO RUN143
P1388-AUTO SHUTDOWN RELAY CONTROL CIRCUIT 146
P1389-NO ASD RELAY OUTPUT VOLTAGE AT PCM 148
P1391-INTERMITTENT LOSS OF CMP OR CKP150
P1398-MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT 154
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND 156
P1491-COOLING FAN RELAY CONTROL CIRCUIT 158
P1492-BATTERY TEMPERATURE SENSOR VOLTAGE TOO HIGH 160
P1493-BATTERY TEMPERATURE SENSOR VOLTAGE TOO LOW 162
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT 164
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT 166
P1594-CHARGING SYSTEM VOLTAGE TOO HIGH 168
P1595-SPEED CONTROL SOLENOID CIRCUITS170
P1683-SPD CTRL PWR RELAY; OR S/C 12V DRIVER CKT 170
P1596-SPEED CONTROL SWITCH ALWAYS HIGH 174
P1597-SPEED CONTROL SWITCH ALWAYS LOW 177
P1682-CHARGING SYSTEM VOLTAGE TOO LOW 179
P1685 WRONG OR INVALID KEY MSG RECEIVED FROM SKIM 182
P1686 NO SKIM BUS MESSAGE RECEIVED 184
P1687-NO CLUSTER BUS MESSAGE 186
P1696-PCM FAILURE EEPROM WRITE DENIED187
P1698-NO BUS MESSAGE FROM TRANS CONTROL MODULE 188
iii
TABLE OF CONTENTS – Continued
P1899-P/N SWITCH PERFORMANCE 190
*BRAKE SWITCH SENSE STATUS DOES NOT CHANGE ON DRBIIIT 192
*CHECKING A/C SYSTEM OPERATION WITH NO DTCS 195
*CHECKING EVAPORATIVE EMISSION OPERATION WITH NO DTCS 198
*CHECKING HARD TO FILL WITH FUEL 200
*CHECKING RADIATOR FAN OPERATION WITH NO DTCS 201
*CHECKING THE PCM POWER AND GROUNDS 203
STARTING
*CHECKING FUEL DELIVERY 204
*CHECKING HARD START (FUEL DELIVERY SYSTEM) 207
*ENGINE CRANKS DOES NOT START209
*FUEL PRESSURE LEAK DOWN 212
*NO CRANK CONDITION 213
*NO RESPONSE FROM PCM WITH A NO START CONDITION216
*START AND STALL CONDITION 219
VERIFICATION TESTS
VERIFICATION TESTS 221
80 COMPONENT LOCATIONS 227
81 CONTROL MODULES AND PDC227
82 DATA LINK CONNECTOR 227
83 SENSORS AND SOLENOIDS 228
84 FUEL SYSTEM 231
85 SWITCHES 232
90 CONNECTOR PINOUTS233
A/C COMPRESSOR CLUTCH233
A/C HIGH PRESSURE SWITCH (40L) 233
A/C LOW PRESSURE SWITCH (24L) 233
A/C LOW PRESSURE SWITCH (40L) 233
A/C PRESSURE TRANSDUCER (24L)234
BATTERY TEMPERATURE SENSOR 234
BRAKE LAMP SWITCH 234
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID 234
C120 (24L) 234
C180235
CAMSHAFT POSITION SENSOR (40L)235
CLOCKSPRING C1235
CLUTCH PEDAL POSITION SWITCH (M/T)235
CRANKSHAFT POSITION SENSOR (24L/40L A/T) 235
CRANKSHAFT POSITION SENSOR (40L M/T) 236
DATA LINK CONNECTOR 236
ENGINE COOLANT TEMPERATURE SENSOR 236
ENGINE OIL PRESSURE SWITCH236
EVAP/PURGE SOLENOID 237
FUEL INJECTOR NO 1 (24L) 237
FUEL INJECTOR NO 1 (40L) 237
FUEL INJECTOR NO 2 (24L) 237
FUEL INJECTOR NO 2 (40L) 237
FUEL INJECTOR NO 3 (24L) 237
iv
TABLE OF CONTENTS – Continued
FUEL INJECTOR NO 3 (40L) 238
FUEL INJECTOR NO 4 (24L) 238
FUEL INJECTOR NO 4 (40L) 238
FUEL INJECTOR NO 5 (40L) 238
FUEL INJECTOR NO 6 (40L) 238
FUEL PUMP MODULE (A/T) 239
FUEL PUMP MODULE (M/T) 239
FUSES (FUSE/RELAY BLOCK) 241
GENERATOR 241
GENERATOR 242
IDLE AIR CONTROL MOTOR242
IGNITION COIL PACK (24L) 242
IGNITION COIL PACK (40L) 242
IGNITION SWITCH 243
INTAKE AIR TEMPERATURE SENSOR243
LEAK DETECTION PUMP 243
MANIFOLD ABSOLUTE PRESSURE SENSOR (40L)243
OVERDRIVE OFF SWITCH 243
OXYGEN SENSOR 1/1 UPSTREAM 244
OXYGEN SENSOR 1/2 DOWNSTREAM 244
OXYGEN SENSOR 2/1 UPSTREAM (EXCEPT EXPORT/JAPAN LOW
EMISSION VEHICLE) 244
OXYGEN SENSOR 2/2 DOWNSTREAM (EXCEPT EXPORT/JAPAN
LOW EMISSION VEHICLE) 244
FUSES (PDC) 246
A/C COMPRESSOR CLUTCH RELAY 246
AUTOMATIC SHUT DOWN RELAY246
ENGINE STARTER MOTOR RELAY 247
OXYGEN SENSOR DOWNSTREAM HEATER RELAY247
POWER STEERING PRESSURE SWITCH (24L)247
POWERTRAIN CONTROL MODULE C1 248
POWERTRAIN CONTROL MODULE C2 249
POWERTRAIN CONTROL MODULE C3 250
RADIATOR FAN MOTOR (24L) 250
RADIATOR FAN MOTOR CIRCUIT BREAKER (24L) 251
RADIATOR FAN MOTOR RELAY (24L)251
SENTRY KEY IMMOBILIZER MODULE251
SPEED CONTROL SERVO 251
THROTTLE POSITION SENSOR (40L)252
VEHICLE SPEED SENSOR 252
100 SCHEMATIC DIAGRAMS 253
110 CHARTS AND GRAPHS257
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
