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2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD 
2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD
2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD
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2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD
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Description
2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD
FILE DETAILS:
2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD
Language : English
Pages : 609
Downloadable : Yes
File Type : PDF
Size: 10.3
TABLE OF CONTENTS:
2004 Jeep Liberty KJ Parts List Manual – PDF DOWNLOAD
2004KJ.......................................................................... 1 Return to Model Year Index.................................................. 0 Return to 2004 Vehicle Family Index......................................... 0 VIN PLATE DECODING INFORMATION.............................................. 1 Group - 1 Component Parts for Mopar Accessories............................. 2 Audio & Electronics..................................................... 3 Fig. 1-110 --> Player Kit - CD Changer.............................. 4 Fig. 1-120 --> Satellite Receiver Kit............................... 5 Fig. 1-130 --> Install Kit - Sattelite Receiver Without CD Chang.... 6 Fig. 1-135 --> Install Kit - Satellite Receiver With CD............. 7 Carriers & Cargo Hauling................................................ 0 Fig. 1-210 --> Bike Carrier - Roof - Fork Mount..................... 8 Fig. 1-215 --> Bike Carrier - Roof - Upright Mount.................. 9 Fig. 1-220 --> Bike Carrier - Spare Tire Mount...................... 10 Fig. 1-225 --> Carrier Kit - Canoe.................................. 11 Fig. 1-230 --> Carrier Kit - Water Sports........................... 12 Fig. 1-235 --> Ski Carrier - Spare Tire Mount....................... 13 Fig. 1-240 --> Ski Carrier - Roof Mount............................. 14 Fig. 1-245 --> Luggage Carrier - Roof - Hard Style.................. 15 Fig. 1-250 --> Luggage Carrier - Roof - Vinyl....................... 16 Fig. 1-255 --> Rack Kit - Sport Utility............................. 17 Fig. 1-260 --> Wiring Kit - Trailer Tow - 4 Way..................... 18 Fig. 1-265 --> Wiring Kit - Trailer Tow - 7 Way..................... 19 Fig. 1-270 --> Fan Kit - Engine..................................... 20 Driving Convenience..................................................... 0 Fig. 1-320 --> Hands Free Kit/Cellular Phone Blue Tooth............. 21 Exterior Appearance..................................................... 0 Fig. 1-410 --> Running Board Kit.................................... 22 Fig. 1-415 --> Wheel Kit............................................ 23 Fig. 1-420 --> Decor Kit Bodyside................................... 24 Exterior Protection..................................................... 0 Fig. 1-510 --> Skid Plate - Transfer Case........................... 25 Fig. 1-515 --> Skid Plate - Fuel Tank............................... 26 Fig. 1-520 --> Deflector Kit - Air Front............................ 27 Fog Lights & Electrical................................................. 0 Fig. 1-610 --> Light Kit - Fog...................................... 28 Fig. 1-615 --> Light Bar Roof....................................... 29 Fig. 1-620 --> Heater Kit........................................... 30 Fig. 1-625 --> Hands Free Kit - Cellular Phone - Blue Tooth......... 31 Interior Storage........................................................ 0 Fig. 1-810 --> Guard Kit - Dog...................................... 32 Security................................................................ 0 Fig. 1-910 --> Alarm - EVS II Base System........................... 33 Fig. 1-915 --> Alarm - EVS II Plus System........................... 34 Group - 2 Front Suspension & Drive.......................................... 35 Front Suspension........................................................ 35 Fig. 2-110 --> Suspension,Front and Strut........................... 36 Fig. 2-120 --> Bar,Front Sway....................................... 39 Front Axle Drive Shafts................................................. 0 Fig. 2-210 --> Axle Shafts,Front.................................... 40 Front Axle Housing...................................................... 0 Fig. 2-310 --> Housing,Axle,Front................................... 41 Front Axle Assembly..................................................... 42 Fig. 2-410 --> Axle Assembly,Front.................................. 43 Front Axle Differential................................................. 0 Fig. 2-610 --> Differential,Front Axle.............................. 45 Front Axle Skid Plate................................................... 51 Fig. 2-810 --> Skid Plate,Front Axle................................ 52 Group - 3 Rear Axle......................................................... 53 Rear Axle............................................................... 53 Fig. 3-110 --> Axle Assembly,Rear,Corporate 8.25 [DRA].............. 54 Differential and Housing................................................ 0 Fig. 3-210 --> Axle,Rear,with Differential and Housing,Corporate.... 55 Rear Axle Vent.......................................................... 0 Fig. 3-310 --> Vent,Rear Axle....................................... 59 Group - 4 Parking Brake..................................................... 60 Parking Brake Lever and Cables.......................................... 60 Fig. 4-110 --> Parking Brake Lever and Cables....................... 61 Fig. 4-120 --> Parking Brake Assembly,Rear,Disc..................... 62 Group - 5 Service Brakes.................................................... 63 Front Brakes............................................................ 63 Fig. 5-110 --> Brakes,Front......................................... 64 Rear Brakes............................................................. 0 Fig. 5-210 --> Brakes,Rear,Disc..................................... 66 Power Brake Booster..................................................... 0 Fig. 5-310 --> Booster,Power Brake.................................. 67 Brake Master Cylinder................................................... 0 Fig. 5-410 --> Master Cylinder,Brake................................ 68 Brake Lines and Hoses................................................... 0 Fig. 5-510 --> Brake Lines,Front,LHD................................ 69 Fig. 5-520 --> Brake Lines,Front,RHD................................ 70 Fig. 5-530 --> Brake Lines,Rear..................................... 71 Brake Pedals............................................................ 0 Fig. 5-610 --> Pedals,Brake and Clutch.............................. 72 Group - 6 Clutch............................................................ 73 Clutch.................................................................. 73 Fig. 6-110 --> Clutch............................................... 74 Clutch Housing.......................................................... 0 Fig. 6-210 --> Clutch Housing....................................... 75 Clutch Controls......................................................... 75 Fig. 6-320 --> Clutch Control....................................... 76 Clutch Pedals........................................................... 0 Fig. 6-420 --> Pedal Clutch......................................... 77 Group - 7 Cooling........................................................... 78 Radiator and Related Parts.............................................. 78 Fig. 7-110 --> Radiator and Related Parts, 2.4L Engine.............. 79 Fig. 7-120 --> Radiator and Related Parts, 3.7L Engine.............. 81 Fig. 7-130 --> Radiator and Related Parts, 2.5,2.8L Diesel Engin.... 83 Water Pump and Related Parts............................................ 0 Fig. 7-210 --> Water Pump and Related Parts, 2.4L Engine............ 85 Fig. 7-220 --> Water Pump and Related Parts, 3.7L Engine............ 86 Fig. 7-230 --> Water Pump and Related Parts, 2.5,2.8L Diesel Eng.... 87 Tank, Coolant Engine.................................................... 88 Fig. 7-305 --> Coolant Tank, 2.4L Engine............................ 89 Fig. 7-310 --> Coolant Tank, 3.7L Engine............................ 90 Fig. 7-320 --> Coolant Degasser Tank, 2.5,2.8L Diesel Engine........ 91 Pulleys and Related Parts............................................... 0 Fig. 7-410 --> Drive Pulleys, 2.4L Engine........................... 92 Fig. 7-420 --> Drive Pulleys, 3.7L Engine........................... 93 Fig. 7-430 --> Drive Pulleys, 2.5,2.8L Diesel Engine................ 94 Drive Belts............................................................. 96 Fig. 7-510 --> Drive Belts, 2.4L Engine............................. 97 Fig. 7-520 --> Drive Belts, 3.7L Engine............................. 98 Fig. 7-530 --> Drive Belts, 2.5,2.8L Diesel Engine.................. 99 Lines, Transmission Oil Cooler.......................................... 99 Fig. 7-610 --> Oil Cooler Lines.....................................100 Grilles.................................................................100 Fig. 7-710 --> Grille and Related Parts.............................101 Group - 8 Electrical........................................................102 Starters................................................................103 Fig. 8-105 --> Starter and Mounting (2.4L Engine) [ED0].............104 Fig. 8-110 --> Starter and Mounting (3.7L Engine) [EK0].............105 Fig. 8-115 --> Starter and Mounting, 4.5L [EN0].....................106 Alternators.............................................................106 Fig. 8-205 --> Alternator (2.4L Engine) [ED0].......................107 Fig. 8-210 --> Alternator (3.7L Engine) [EK0].......................108 Fig. 8-215 --> Alternator (2.5L Diesel Engine) [EN0]................109 Modules.................................................................110 Fig. 8-410 --> Modules..............................................111 Relays.................................................................. 0 Fig. 8-510 --> Junction Block, Relays, Circuit Breaker..............114 Sensors.................................................................114 Fig. 8-605 --> Sensor, Engine (2.4L Engine) [ED0]...................115 Fig. 8-610 --> Sensors, Engine (3.7L Engine) [EK0]..................116 Fig. 8-615 --> Sensors, Engine (2.5L Diesel) [EN0]..................117 Fig. 8-620 --> Sensors, Oxygen 2.4L [ED0]...........................119 Fig. 8-625 --> Sensors, Oxygen 3.7L [EK0]...........................120 Fig. 8-635 --> Sensor (Drive Train).................................121 Fig. 8-640 --> Sensor (Body)........................................122 Single Board Engine Controllers......................................... 0 Fig. 8-710 --> JTEC Modules & Solenoids.............................123 Switches................................................................ 0 Fig. 8-810 --> Switches (Instrument Panel and Console)..............124 Fig. 8-820 --> Switches (Drive Train)...............................127 Fig. 8-830 --> Switches (Body)......................................128 Horns...................................................................129 Fig. 8-910 --> Horns................................................130 Battery Tray and Cables................................................. 0 Fig. 8-1010 --> Battery Tray & Cables...............................131 Lamps - Front, Rear and Courtesy........................................ 0 Fig. 8-1110 --> Lamp, Front.........................................133 Fig. 8-1115 --> Lamps Roof (Renegade)...............................136 Fig. 8-1120 --> Lamp, Rear..........................................137 Fig. 8-1130 --> Lamp, Courtesy......................................139 Fig. 8-1135 --> Bulbs...............................................140 Wiring-Engine & Related Parts........................................... 0 Fig. 8-1210 --> Wiring, Engine & Related Parts......................141 Wiring-Headlamp to Dash................................................. 0 Fig. 8-1310 --> Wiring, Headlamp / Dash.............................143 Wiring-Instrument Panel................................................. 0 Fig. 8-1410 --> Wiring Instrument Panel.............................145 Wiring-Body & Accessories............................................... 0 Fig. 8-1510 --> Wiring, Body & Accessories..........................146 Wiring Repair........................................................... 0 Fig. 8-1610 --> Wiring, Repair Package..............................151 Air Bag Systems......................................................... 0 Fig. 8-1705 --> Air Bag Module and Sensors..........................152 Fig. 8-1710 --> Air Bags and Clock Spring...........................153 Spark Plugs-Cables-Coils................................................ 0 Fig. 8-1910 --> Spark Plug - Coil...................................154 Group - 08A Instrument Panel and Radios and Consoles........................155 Instrument Panel........................................................155 Fig. 08A-110 --> Instrument Panel...................................156 Instrument Panel Cluster................................................ 0 Fig. 08A-210 --> Instrument Panel Cluster...........................167 Radio, Antenna, and Speakers............................................ 0 Fig. 08A-310 --> Radios.............................................169 Fig. 08A-320 --> Speakers...........................................171 Fig. 08A-330 --> Antenna............................................172 Consoles................................................................ 0 Fig. 08A-410 --> Console, Overhead..................................173 Fig. 08A-420 --> Console, Floor.....................................175 Group - 9 Engine Mounting...................................................178 Engine Mounting.........................................................178 Fig. 9-110 --> Front, Engine Mounting...............................179 Fig. 9-115 --> Front, Engine Mounting...............................180 Fig. 9-120 --> Front, Engine Mounting...............................181 Fig. 9-125 --> Front, Engine Mounting...............................182 Fig. 9-130 --> Rear, Transmission Mounting..........................183 Fig. 9-135 --> Rear, Transmission Mounting..........................184 Fig. 9-140 --> Rear, Transmission Mounting..........................185 Fig. 9-145 --> Rear, Transmission Mounting..........................186 Fig. 9-150 --> Rear, Transmission Mounting..........................187 Fig. 9-155 --> Rear, Transmission Mounting..........................188 Fig. 9-160 --> Rear, Transmission Mounting..........................189 Fig. 9-165 --> Rear, Transmission Mounting..........................190 Group - 2.4L Engine 2.4L Four Cylinder......................................191 Cylinder Head...........................................................191 Fig. 2.4L-210 --> Cylinder Head, 2.4L [ED1].........................192 Cylinder Block.......................................................... 0 Fig. 2.4L-310 --> Cylinder Block, 2.4L [ED1]........................193 Crankshaft, Piston, and Drive Plate..................................... 0 Fig. 2.4L-410 --> Crankshaft, Pistons and Flywheel, 2.4L [ED1]......194 Camshafts and Valves.................................................... 0 Fig. 2.4L-510 --> Camshaft and Valves 2.4L [ED1]....................195 Timing Belt and Cover...................................................195 Fig. 2.4L-610 --> Timing Belt and Cover, 2.4L [ED1].................196 Fig. 2.4L-620 --> Balance Shafts, 2.4L [ED1]........................197 Engine Oiling........................................................... 0 Fig. 2.4L-710 --> Engine Oiling, 2.4L [ED1].........................198 Manifolds............................................................... 0 Fig. 2.4L-810 --> Intake and Exhaust Manifolds, 2.4L [ED1]..........199 Crankcase Ventilation................................................... 0 Fig. 2.4L-910 --> Crankcase Ventilation , 2.4L [ED1]................200 Group - 3.7L Engine 3.7L Six Cylinder.......................................201 Cylinder Head...........................................................202 Fig. 3.7L-210 --> Cylinder Head 3.7L [EKG]..........................203 Cylinder Block.......................................................... 0 Fig. 3.7L-310 --> Cylinder Block, 3.7L [EKG]........................205 Crankshaft, Piston and Torque Converter................................. 0 Fig. 3.7L-410 --> Crankshaft, Pistons and Flywheel, 3.7L [EKG]......206 Camshafts & Valves...................................................... 0 Fig. 3.7L-510 --> Camshaft And Valve, 3.7L [EKG]....................208 Timing Belt and Cover................................................... 0 Fig. 3.7L-610 --> Timing Cover, 3.7L [EKG]..........................209 Fig. 3.7L-620 --> Timing Chain and Guides, 3.7L [EKG]...............210 Engine Oiling........................................................... 0 Fig. 3.7L-710 --> Engine Oiling, 3.7L [EKG].........................211 Manifolds............................................................... 0 Fig. 3.7L-810 --> Manifolds, Intake and Exhaust, 3.7L [EKG].........212 Crankcase Ventilation................................................... 0 Fig. 3.7L-910 --> Crankcase Ventilation, 3.7L [EKG].................213 Group - 2.5LD Engine 2.5L Four Cylinder (Turbo Diesel)......................214 Cylinder Head...........................................................214 Fig. 2.5LD-210 --> Cylinder Head 2.5L [ENJ].........................215 Fig. 2.5LD-220 --> Rocker Cover and Rocker Cover Assembly 2.5L [....217 Cylinder Block.......................................................... 0 Fig. 2.5LD-310 --> Cylinder Block 2.5L [ENJ]........................218 Crankshaft, Piston and Drive Plate...................................... 0 Fig. 2.5LD-410 --> Crankshaft,Pistons and Related Parts 2.5L [EN....220 Camshafts & Valves...................................................... 0 Fig. 2.5LD-510 --> Camshaft and Valves 2.5L [ENJ]...................222 Timing Belt and Cover................................................... 0 Fig. 2.5LD-610 --> Timing Cover and Related Parts 2.5L [ENJ]........223 Engine Oiling...........................................................224 Fig. 2.5LD-710 --> Engine Oiling and Balance Shafts 2.5L [ENJ]......225 Fig. 2.5LD-720 --> Oil Cooler 2.5L [ENJ]............................227 Fig. 2.5LD-730 --> Engine Oil Filter Adapter And Lines 2.5L Dies....229 Manifolds...............................................................230 Fig. 2.5LD-810 --> Manifolds 2.5L [ENJ].............................231 Crankcase Ventilation................................................... 0 Fig. 2.5LD-910 --> Crankcase Ventilation 2.5L [ENJ].................232 Group - 2.8L Engine 2.8L Four Cylinder (Turbo Diesel).......................233 Cylinder Head...........................................................233 Fig. 2.8L-210 --> Cylinder Head 2.8 DieseL [ENR]....................234 Fig. 2.8L-220 --> Rocker Cover and Rocker Cover Assembly 2.8L Di....236 Cylinder Block.......................................................... 0 Fig. 2.8L-310 --> Cylinder Block 2.8 Diesel [ENR]...................237 Crankshaft, Piston and Drive Plate...................................... 0 Fig. 2.8L-410 --> Crankshaft,Pistons and Related, 2.8L Diesel [E....239 Camshafts & Valves...................................................... 0 Fig. 2.8L-510 --> Camshaft and Valves,2.8L Diesel [ENR].............241 Timing Belt and Cover................................................... 0 Fig. 2.8L-610 --> Timing Cover And Related 2.8 Diesel [ENR].........242 Engine Oiling........................................................... 0 Fig. 2.8L-710 --> Engine Oiling 2.8 Diesel [ENR]....................243 Fig. 2.8L-720 --> Oil Line 2.8 Diesel [ENR].........................245 Fig. 2.8L-730 --> Engine Oil Filter Adapter And Lines 2.8L Diese....247 Manifolds...............................................................248 Fig. 2.8L-810 --> Manifolds, 2.8L Diesel [ENR]......................249 Crankcase Ventilation................................................... 0 Fig. 2.8L-910 --> Crankcase Ventilation 2.8 Diesel [ENR]............250 Group - 11 Exhaust..........................................................251 Exhaust System..........................................................251 Fig. 11-110 --> Exhaust System, 2.8L [EN0]..........................252 Fig. 11-120 --> Exhaust System 2.4L [ED1]...........................253 Fig. 11-130 --> Exhaust System 3.7L [EKG]...........................254 Heat Shields............................................................ 0 Fig. 11-210 --> Heat Shields........................................255 Group - 13 Frames and Bumpers...............................................256 Frames..................................................................256 Fig. 13-110 --> Frame Cradle........................................257 Front Bumper and Fascia................................................. 0 Fig. 13-210 --> Bumper, Front.......................................258 Rear Bumper and Fascia.................................................. 0 Fig. 13-310 --> Bumper, Rear........................................259 Trailer Tow............................................................. 0 Fig. 13-610 --> Tow Hooks - Front...................................260 Fig. 13-620 --> Tow Hooks - Rear....................................261 Group - 14 Fuel.............................................................262 Tank, Fuel..............................................................263 Fig. 14-110 --> Tank, Fuel, All Engines.............................264 Fuel Tank Filler Tube................................................... 0 Fig. 14-210 --> Fuel Tank Filler Tube, All Engines..................265 Fuel Lines.............................................................. 0 Fig. 14-310 --> Fuel Lines Front, 2.4L [ED1]........................266 Fig. 14-315 --> Fuel Lines Rear, 2.4L [ED1].........................267 Fig. 14-320 --> Fuel Lines Front, 3.7L [EKG]........................268 Fig. 14-325 --> Fuel Lines Rear, 3.7L [EKG].........................269 Fig. 14-330 --> Fuel Lines Front 2.8L [EN0].........................270 Fig. 14-335 --> Fuel Lines Chassis 2.8L [EN0].......................271 Fig. 14-340 --> Fuel Filter And Water Separator, 2.8L [EN0].........272 Fuel Rail...............................................................272 Fig. 14-405 --> Fuel Rail 2.8L [EN0]................................273 Fig. 14-410 --> Fuel Rail, 2.4L [ED0]...............................276 Fig. 14-415 --> Fuel Rail, 3.7L [EK0]...............................277 Fig. 14-420 --> Fuel Injection System 2.8L [EN0]....................278 Fig. 14-430 --> Fuel Injection Pump 2.8L [EN0]......................280 Fig. 14-435 --> Fuel Injection Pump Mounting........................282 Fuel Pump and Sending Unit..............................................283 Fig. 14-510 --> Fuel Pump and Sending Unit, 2.4L [ED0], 3.7L [EK....284 Throttle Body........................................................... 0 Fig. 14-610 --> Throttle Body, [2.4L ED0, 3.7L EK0].................285 Fig. 14-620 --> Turbocharger 2.8L [EN0].............................286 Throttle Controls....................................................... 0 Fig. 14-710 --> Throttle Controls, 2.4L [ED0].......................287 Fig. 14-720 --> Throttle Controls, 3.7L [EKG].......................288 Fig. 14-730 --> Throttle Controls, 2.8L [EN0].......................289 Air Cleaner............................................................. 0 Fig. 14-810 --> Air Cleaner, 2.4L [ED1].............................290 Fig. 14-820 --> Air Cleaner, 3.7L [EKG].............................291 Fig. 14-830 --> Air Cleaner, 2.8L [EN0].............................292 Speed Control........................................................... 0 Fig. 14-1010 --> Speed Control......................................293 Accelerator Pedal....................................................... 0 Fig. 14-1110 --> Accelerator Pedal..................................294 Group - 16 Propeller Shafts and U-Joints....................................295 Propeller Shaft.........................................................295 Fig. 16-110 --> Propeller Shaft,2 Wheel Drive.......................296 Fig. 16-120 --> Propeller Shaft,4 Wheel Drive.......................297 Group - 17 Rear Suspension..................................................299 Rear Suspension.........................................................299 Fig. 17-110 --> Suspension,Rear and Shock...........................300 Rear Stabilizer......................................................... 0 Fig. 17-210 --> Stabilizer Bar,Rear.................................302 Group - 19 Steering.........................................................303 Steering Wheel..........................................................303 Fig. 19-110 --> Steering Wheel......................................304 Steering Column......................................................... 0 Fig. 19-210 --> Column,Steering.....................................306 Steering Gear........................................................... 0 Fig. 19-310 --> Gear Assembly, Steering, Rack and Pinion............308 Power Steering Pump..................................................... 0 Fig. 19-510 --> Pump,Power Steering,2.4L [ED0] Gas Engine...........311 Fig. 19-520 --> Pump,Power Steering,2.8L [EN0] Diesel Engine........312 Fig. 19-530 --> Pump,Power Steering,3.7L [EK0] Gas Engine...........313 Power Steering Hoses.................................................... 0 Fig. 19-710 --> Hoses and Reservoir,LHD,2.4L [ED0] 2.8L [EN0].......314 Fig. 19-720 --> Hoses and Reservior, RHD 2.4L [ED0] 2.8L [EN0]......316 Fig. 19-730 --> Hoses and Reservior, LHD, 3.7L [EK0]................318 Fig. 19-740 --> Hoses and Reservior, RHD, 3.7L [EK0]................319 Group - 42RLE Automatic Transaxle 4 Speed...................................320 Transaxle Assembly......................................................320 Fig. 42RLE-110 --> Tranmission Asembly..............................321 Fig. 42RLE-120 --> Overhaul Seal & Gasket Package...................322 Case and Extension......................................................322 Fig. 42RLE-210 --> Case, Transmission...............................323 Fig. 42RLE-220 --> Adapter & Extension..............................325 Fig. 42RLE-230 --> Mounting, Transmission...........................326 Fig. 42RLE-240 --> Collar, Structural...............................327 Oil Pump................................................................ 0 Fig. 42RLE-310 --> Oil Pump & Reaction Shaft........................328 Gear Train.............................................................. 0 Fig. 42RLE-410 --> Clutch, Input Shaft..............................330 Fig. 42RLE-420 --> Gear Train.......................................337 Valve Body.............................................................. 0 Fig. 42RLE-710 --> Valve Body.......................................345 Fig. 42RLE-720 --> Accumulator Pistons & Springs....................348 Fig. 42RLE-730 --> Parking Sprag....................................349 Gearshift Controls......................................................349 Fig. 42RLE-1210 --> Gearshift Control...............................350 Group - 5-45RFE Automatic Transmission Multi-Speed..........................351 Transmission Assembly...................................................352 Fig. 5-45RFE-110 --> Transmission Assembly [DGQ]....................353 Case and Extension...................................................... 0 Fig. 5-45RFE-210 --> Transmission Mounting..........................354 Fig. 5-45RFE-220 --> Adapter........................................355 Fig. 5-45RFE-230 --> Case & Related Parts...........................356 Fig. 5-45RFE-240 --> Transmission Overhaul Package..................357 Oil Pump................................................................ 0 Fig. 5-45RFE-310 --> Oil Pump.......................................358 Gear Train.............................................................. 0 Fig. 5-45RFE-410 --> Input Shaft....................................359 Fig. 5-45RFE-420 --> Underdrive.....................................361 Fig. 5-45RFE-430 --> Overdrive......................................362 Fig. 5-45RFE-440 --> 2 / 4 Clutch Retainer..........................363 Fig. 5-45RFE-450 --> Input / Reverse Planetary......................365 Fig. 5-45RFE-460 --> Reaction Annulus / Sun Gear....................366 Fig. 5-45RFE-470 --> Low / Reverse Clutch...........................367 Valve Body.............................................................. 0 Fig. 5-45RFE-710 --> Valve Body.....................................368 Fig. 5-45RFE-730 --> Parking Sprag..................................369 Gearshift Controls...................................................... 0 Fig. 5-45RFE-1210 --> Gearshift Controls............................370 Seal and Shim Packages.................................................. 0 Fig. 5-45RFE-1310 --> L / R Clutch..................................371 Fig. 5-45RFE-1320 --> Input Clutch Plate............................372 Fig. 5-45RFE-1330 --> O / H.........................................373 Fig. 5-45RFE-1340 --> Input Clutch..................................374 Fig. 5-45RFE-1350 --> Planetary Plate...............................375 Fig. 5-45RFE-1360 --> 2 & 4 Clutch..................................376 Group - 3550 Manual Transmission 5 Speed....................................377 Transmission Assembly...................................................377 Fig. 3550-110 --> Transmission Assembly [DDD].......................378 Case and Extension...................................................... 0 Fig. 3550-210 --> Case and Extension [DDD]..........................379 Gear Train..............................................................382 Fig. 3550-410 --> Gear Train [DDD]..................................383 Fork and Rails.......................................................... 0 Fig. 3550-910 --> Fork and Rails [DDD]..............................390 Gearshift Controls......................................................392 Fig. 3550-1210 --> Gearshift Controls [DDD].........................393 Group - NV1500 Manual Transmission 5 Speed..................................394 Transmission Assembly...................................................395 Fig. NV1500-110 --> Transmission [NV 1500] [DDK]....................396 Case and Extension...................................................... 0 Fig. NV1500-210 --> Case and Extension [NV 1500] [DDK]..............397 Gear Train..............................................................400 Fig. NV1500-410 --> Gear Train [NV 1500] [DDK]......................401 Fork and Rails..........................................................407 Fig. NV1500-910 --> Fork and Rail [NV 1500] [DDK]...................408 Gearshift Controls......................................................409 Fig. NV1500-1210 --> Gearshift Controls [DDK].......................410 Group - 231 Transfer Case Model 231 [DHN]...................................411 Transfer Case Assembly..................................................411 Fig. 231-110 --> Transfer Case Command Trac [DHN]...................412 Case and Related Parts.................................................. 0 Fig. 231-210 --> Case and Related Parts Command Trac [DHN]..........413 Gear Train.............................................................. 0 Fig. 231-410 --> Gear Train Command Trac [DHN]......................415 Fork and Rails.......................................................... 0 Fig. 231-910 --> Forks and Rails Command Trac [DHN].................417 Gearshift Controls...................................................... 0 Fig. 231-1210 --> Gearshift Controls................................418 Group - 242 Transfer Case Model 242 [DHP]...................................419 Transfer Case Assembly..................................................419 Fig. 242-110 --> Transfer Case Select Trac [DHP]....................420 Case and Related Parts..................................................420 Fig. 242-210 --> Case and Related Parts Select Trac [DHP]...........421 Gear Train.............................................................. 0 Fig. 242-410 --> Gear Train Select Trac [DHP].......................425 Fork and Rails..........................................................429 Fig. 242-910 --> Forks and Rails Select Trac [DHP]..................430 Gearshift Controls......................................................432 Fig. 242-1210 --> Gearshift Controls................................433 Group - 22 Wheels, Covers and Jacks.........................................434 Wheels and Hardware.....................................................434 Fig. 22-110 --> Wheels and Hardware.................................435 Wheel Covers and Center Caps............................................ 0 Fig. 22-210 --> Wheel Caps..........................................436 Jack Stowage............................................................ 0 Fig. 22-310 --> Jack and Hardware...................................437 Spare Tire Stowage...................................................... 0 Fig. 22-410 --> Spare Wheel.........................................438 Fig. 22-420 --> Spare Wheel, Export.................................439 Group - 23D Wiper/Lock Cylinder and Keys....................................440 Lock Cylinders and Keys.................................................440 Fig. 23D-110 --> Lock Cylinder and Keys.............................441 Windshield Wiper and Washer Systems..................................... 0 Fig. 23D-210 --> Windshield Wiper & Washer..........................444 Rear Wiper and Washer System............................................ 0 Fig. 23D-310 --> Rear Wiper & Washer................................446 Group - 24 Air Conditioning & Heater........................................447 Air Conditioner and Heater Units........................................447 Fig. 24-110 --> HEVAC Unit..........................................448 Air Conditioner and Heater Plumbing..................................... 0 Fig. 24-210 --> Plumbing, Heater 2.4L Engine, LHD...................451 Fig. 24-220 --> Plumbing, Heater 2.4L Engine, RHD...................452 Fig. 24-230 --> Plumbing, Heater 3.7L Engine, LHD...................453 Fig. 24-240 --> Plumbing, Heater 3.7L Engine, RHD...................454 Fig. 24-250 --> Plumbing, Heater 2.5,2.8L Diesel Engine, LHD........455 Fig. 24-260 --> Plumbing, Heater 2.5,2.8L Diesel Engine, RHD........456 Fig. 24-270 --> Plumbing, Air Conditioning 2.4L Engine, LHD.........457 Fig. 24-280 --> Plumbing, Air Conditioning 2.4L Engine, RHD.........458 Fig. 24-285 --> Plumbing, Air Conditioning 3.7L Engine, LHD.........459 Fig. 24-288 --> Plumbing, Air Conditioning 3.7L Engine, RHD.........460 Fig. 24-290 --> Plumbing, Air Conditioning 2.5,2.8L Diesel Engin....461 Fig. 24-295 --> Plumbing, Air Conditioning 2.5,2.8L Diesel Engin....462 Air Conditioner and Heater Controls..................................... 0 Fig. 24-310 --> Control, Heater and Air Conditioning................463 Air Conditioning Compressor............................................. 0 Fig. 24-410 --> Compressor, 2.4L - 3.7L Engine......................464 Fig. 24-430 --> Compressor, 2.5,2.8L Diesel Engine..................465 Air Conditioning Compressor Mounting.................................... 0 Fig. 24-510 --> Compressor Mounting, 2.4L - 3.7L Engine.............466 Fig. 24-530 --> Compressor Mounting, 2.5,2.8L Diesel Engine.........467 Air Ducts and Outlets................................................... 0 Fig. 24-610 --> Air Distribution Ducts..............................468 Group - 25 Emission Systems.................................................469 EGR System..............................................................469 Fig. 25-210 --> EGR System 2.8L [EN0]...............................470 Vacuum Canister.........................................................471 Fig. 25-310 --> Vapor Canister 2.4L [ED1], 3.7L [EKG]...............472 Emission Harness........................................................ 0 Fig. 25-410 --> Emission Vacuum Harness 2.8L [EN0]..................473 Fig. 25-420 --> Emission Vacuum Harness 2.4L [ED1], 3.7L [EKG]......474 Fig. 25-430 --> Leak Detection Pump, 2.4L [ED1], 3.7L [EKG].........475 Group - DKJ Doors and Related Parts.........................................476 Front Door..............................................................476 Fig. DKJ-110 --> Door, Front, Shell and Hinges......................477 Fig. DKJ-120 --> Door, Front, Glass and Regulator...................478 Fig. DKJ-130 --> Door, Front, Lock and Controls.....................479 Rear Door............................................................... 0 Fig. DKJ-210 --> Door, Rear, Shell and Hinges.......................481 Fig. DKJ-220 --> Door, Rear, Glass and Regulator....................482 Fig. DKJ-230 --> Door, Rear, Lock and Controls......................483 Exterior Mirror......................................................... 0 Fig. DKJ-510 --> Mirrors, Exterior..................................485 Weatherstrips and Seals................................................. 0 Fig. DKJ-610 --> Door, Front........................................487 Fig. DKJ-620 --> Door, Rear.........................................488 Group - EKJ Exterior Ornamentation..........................................489 Nameplates..............................................................489 Fig. EKJ-110 --> Nameplates.........................................490 Moldings and Ornamentation.............................................. 0 Fig. EKJ-210 --> Moldings, Body Side................................491 Fig. EKJ-220 --> Side Rails, Tubular [MRK]..........................498 Decals and Tapestripes.................................................. 0 Fig. EKJ-310 --> Decals.............................................499 Group - IKJ Interior Trim...................................................500 Headliner and Visor.....................................................501 Fig. IKJ-110 --> Headliner and Visors...............................502 Moldings, Scuff Plates.................................................. 0 Fig. IKJ-210 --> Panels, Interior Trim, Front.......................509 Fig. IKJ-220 --> Panels, Interior Trim, Rear........................510 Carpet.................................................................. 0 Fig. IKJ-310 --> Carpets and Mats...................................511 Fig. IKJ-320 --> Cargo Organizer....................................514 Door Trim Panels........................................................ 0 Fig. IKJ-410 --> Trim Panel, Front Door.............................515 Fig. IKJ-420 --> Trim Panel, Rear Door..............................519 Front Seats and Attaching Parts......................................... 0 Fig. IKJ-510 --> Front Seat, Leather, Low Back, Trim Code [DL]......521 Fig. IKJ-520 --> Front Seat, Cloth, Low Back, Trim Code [XJ]........526 Fig. IKJ-530 --> Front Seat, Cloth, Trim Code [M5]..................528 Fig. IKJ-540 --> Front Seat, Cloth, Low Back, Trim Code [E7]........529 Fig. IKJ-550 --> Front Seat, Cloth, Trim Code [J5]..................530 Fig. IKJ-560 --> Front Seat, Cloth, Low Back, Trim Code [F7]........531 Fig. IKJ-570 --> Front Seat, Cloth, Low Back, Trim Code [A7]........532 Fig. IKJ-580 --> Front Seat, Cloth, Trim Code [V5]..................533 Rear Seats and Attaching Parts.......................................... 0 Fig. IKJ-610 --> Rear Seats, Trim Code [M5].........................534 Fig. IKJ-620 --> Rear Seat, Trim Code [DL]..........................537 Fig. IKJ-630 --> Rear Seat, Trim Code [XJ]..........................543 Fig. IKJ-640 --> Rear Seat, Trim Code [E7]..........................548 Fig. IKJ-650 --> Rear Seat, Trim Code [J5]..........................551 Fig. IKJ-660 --> Rear Seat, Trim Code [F7]..........................554 Fig. IKJ-670 --> Rear Seat, Trim Code [A7]..........................557 Fig. IKJ-680 --> Rear Seat, Trim Code [V5]..........................559 Seat Belts-Front and Rear............................................... 0 Fig. IKJ-710 --> Seat Belts, Front..................................561 Fig. IKJ-720 --> Seat Belts, Rear...................................563 Adjusters, Covers, Shields, and Risers..................................565 Fig. IKJ-810 --> Recliner and Adjuster..............................566 Lift Gate Trim.......................................................... 0 Fig. IKJ-1010 --> Swing Gate Trim Panel.............................579 Group - SKJ Body Sheet Metal Except Doors...................................580 Floor Pans..............................................................581 Fig. SKJ-210 --> Front Floor Pan....................................582 Fig. SKJ-220 --> Rear Floor Pan.....................................583 Fig. SKJ-230 --> Plates, Underbody Skid.............................584 Plugs................................................................... 0 Fig. SKJ-310 --> Plugs..............................................585 Front Fenders........................................................... 0 Fig. SKJ-410 --> Front Fender.......................................586 Hood & Hood Release..................................................... 0 Fig. SKJ-510 --> Hood, Latch and Hinges.............................588 Cowl and Dash Panel..................................................... 0 Fig. SKJ-610 --> Cowl and Dash Panel................................589 Glass and Rear View Mirror..............................................589 Fig. SKJ-710 --> Windshield, Quarter Window, Backlite and Mirror....590 Aperture Panel.......................................................... 0 Fig. SKJ-810 --> Panels, Body Side..................................592 Quarter Panel and Pillar................................................ 0 Fig. SKJ-910 --> Panels, Rear Quarter...............................593 Fig. SKJ-920 --> Fuel Filler Housing and Door.......................595 Roof Panels............................................................. 0 Fig. SKJ-1110 --> Roof Panel........................................596 Sunroof................................................................. 0 Fig. SKJ-1210 --> Sunroof...........................................597 Liftgate Panel.......................................................... 0 Fig. SKJ-1310 --> Swing Gate, Latch, and Hinges.....................598 Luggage Rack............................................................ 0 Fig. SKJ-1610 --> Luggage Rack......................................600 Group - LBLS Labels All Vehicle Locations...................................601 Interior................................................................601 Fig. LBLS-110 --> Instrument Panel, Visors & Trim...................602 Under Hood.............................................................. 0 Fig. LBLS-210 --> Engine Compartment................................603 Doors................................................................... 0 Fig. LBLS-310 --> Door and Pillars..................................605 Fig. LBLS-320 --> Rear Glass........................................606 Exterior................................................................606 Fig. LBLS-410 --> Fuel Door/Filler..................................607 Rear Cargo & Storage.................................................... 0 Fig. LBLS-510 --> Jack Assembly.....................................608 Fig. LBLS-520 --> Rear Cargo........................................609
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