Jeep KJ 2005 Manual de usuario

GROUP TAB LOCATOR

Introduction

0Lubrication & Maintenance

2Suspension

3Differential & Driveline

5Brakes

6Clutch

7Cooling

8A Audio/Video

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8T Navigation/Telecommunication

8W Wiring

9Engine

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)

INTRODUCTION

TABLE OF CONTENTS

page page

FASTENER IDENTIFICATION

DESCRIPTION ..........................1

FASTENER USAGE

DESCRIPTION

DESCRIPTION ........................4

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................4

METRIC SYSTEM

DESCRIPTION ..........................4

TORQUE REFERENCES

DESCRIPTION ..........................6

VEHICLE EMISSION CONTROL INFORMATION

(VECI) LABEL

DESCRIPTION ..........................8

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION ..........................8

VEHICLE CERTIFICATION LABEL

DESCRIPTION ..........................9

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. 1).

BOLT MARKINGS AND TORQUES - METRIC

Bolt Markings 8.8/8.9 10.9 12.9

Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.

6 12 105* 14 120* 16 12

8 25 250* 32 23 38 28

10 54 40 60 45 74 55

12 95 70 108 80 135 100

14 155 115 175 130 216 160

16 243 180 324 210 324 240

* Inch Lbs.

KJ INTRODUCTION 1

BOLT MARKINGS AND TORQUES - U. S. CUSTOMARY

Bolt Markings Grade 5 Grade 8

Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs

1/4 - 20 10 95* 14 125*

1/4 - 28 10 95* 17 150*

5/16 - 18 22 200* 30 270*

5/16 - 24 26 240* 33 300*

3/8-1640305540

3/8-2447356045

7/16-1468508865

7/16-2074559570

1/2 - 13 101 75 135 100

1/2 -20 115 85 150 110

9/16 - 12 135 105 182 135

9/16 - 18 155 115 202 150

5/8 - 11 202 150 263 195

5/8 - 18 215 160 284 210

3/4 - 10 230 170 297 220

3/4 - 16 236 175 304 225

7/8 - 14 405 300 540 400

* Inch Lbs.

2 INTRODUCTION KJ

FASTENER IDENTIFICATION (Continued)

Fig. 1 FASTENER STRENGTH

KJ INTRODUCTION 3

FASTENER IDENTIFICATION (Continued)

FASTENER USAGE

DESCRIPTION

WARNING: Use of an incorrect fastener may result

in component damage or personal 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

Most stripped threaded holes can be repaired using

a Helicoilt. Follow the vehicle or Helicoiltrecommen-

dations for application and repair procedures.

INTERNATIONAL SYMBOLS

DESCRIPTION

The graphic symbols illustrated in (Fig. 2) and the

following International Control and Display Symbols

Chart are used to identify various instrument con-

trols. The symbols correspond to the controls and dis-

plays that are located on the instrument panel.

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one,

ten, one hundred, one thousand and one million.

The following chart (Fig. 3) will assist in convert-

ing metric units to equivalent English and SAE

units, or vise versa.

Fig. 2 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 KJ

Fig. 3 METRIC CONVERSION CHART

KJ INTRODUCTION 5

METRIC SYSTEM (Continued)

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 (Fig. 3) to

convert torque values listed in metric Newton-

meters (N·m). Also, use the chart to convert between

millimeters (mm) and inches (in.).

TORQUE REFERENCES

DESCRIPTION

Individual Torque Charts appear within many or

the Groups. Refer to the Standard Torque Specifica-

tions Chart (Fig. 4) for torque references not listed in

the individual torque charts.

6 INTRODUCTION KJ

METRIC SYSTEM (Continued)

Fig. 4 TORQUE SPECIFICATIONS

KJ INTRODUCTION 7

TORQUE REFERENCES (Continued)

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.

5). The label cannot be removed without defacing

label information and destroying 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 label also contains an engine vacuum sche-

matic. There are unique labels for vehicles built for

sale in the state of California and the country of

Canada. Canadian labels are written in both the

English and French languages.

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

VEHICLE IDENTIFICATION

NUMBER

DESCRIPTION

The Vehicle Identification Number (VIN) plate is

located on the lower left A-pillar and is visible

through the windshield (Fig. 6). The VIN contains 17

characters that provide data concerning the vehicle.

Refer to the VIN decoding 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. 5 VECI LABEL LOCATION

1 - RADIATOR SUPPORT

2 - VECI LABEL

Fig. 6 VIN NUMBER LOCATION

1 - A-PILLAR

2 - VIN CODE PLATE

8 INTRODUCTION KJ

VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured by DaimlerChrysler

Corporation

2 Make J = Jeep

3 Vehicle Type 4 = MPV W/O Side Airbags.

8 = MPV With Side Airbags.

4 Gross Vehicle Weight Rating F = 4001 - 5000 lbs.

G = 5001 - 6000 lbs.

5 Vehicle Line K = Liberty 4X2 (LHD)

L = Liberty 4X4 (LHD) wihtout ABB

M = Cherokee 4X4 (RHD)

6 = Cherokee (LHD) with ABB

6 Series 3 = Liberty/Renegade

4 = Liberty Sport/Cherokee Sport

5 = Liberty Limited/Cherokee Limited

7 Body Style 8 = Sport Utility - 4 Door

8 Engine K = 3.7L 6 cyl MPI Gasoline

1 = 2.4L 4 cyl MPI Gasoline

5 = 2.8L 4 cyl Diesel

9 Check Digit 0 through 9 or X

10 Model Year 5=2005

11 Assembly Plant W = Toledo North Assembly Plant

12 thru 17 Vehicle Build Sequence

VEHICLE CERTIFICATION

LABEL

DESCRIPTION

A vehicle certification label (Fig. 7) is attached to

every DaimlerChrysler Corporation vehicle. The label

certifies that the vehicle conforms to all applicable

Federal Motor Vehicle 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. 7 VEHICLE CERTIFICATION LABEL - TYPICAL

KJ INTRODUCTION 9

VEHICLE IDENTIFICATION NUMBER (Continued)

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