Lamps JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

LINE PRESSURE SENSOR (4.7L) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 Z114 14BK/LB GROUND
2 T138 14GY/LB 5 VOLT SUPPLY
3 T130 14VT/TN LINE PRESSURE SENSOR SIGNAL
4- -
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.0L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K1 18DG/RD MAP SENSOR SIGNAL
3 K7 18OR 5 VOLT SUPPLY
MANIFOLD ABSOLUTE PRESSURE SENSOR (4.7L) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K1 18DG/RD MAP SENSOR SIGNAL
2 K4 18BK/LB SENSOR GROUND
3 K7 18OR 5 VOLT SUPPLY
MANUAL TEMPERATURE CONTROL C1 (MTC) - WHITE 11 WAY
CAV CIRCUIT FUNCTION
1 C103 20DG A/C SWITCH SIGNAL
2 Z123 20BK/OR GROUND
3 C67 20RD/LB BLEND AIR DOOR POSITION CONTROL
4 C79 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
5 C81 20LB/WT REAR WINDOW DEFOGGER SWITCH SENSE
6 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
7 E2 20OR PANEL LAMPS DRIVER
8 C4 16TN BLOWER MOTOR LOW DRIVER
9 C5 16LG BLOWER MOTOR M1 DRIVER
10 C6 14LB BLOWER MOTOR M2 DRIVER
11 - -
8W - 80 - 98 8W-80 CONNECTOR PIN-OUTWJ

PASSENGER HEATED SEAT CUSHION (PREMIUM I/III)-4WAY
CAV CIRCUIT FUNCTION
1 P130 16DG/WT PASSENGER SEAT HEATER B(+) DRIVER
2 P88 16BK/BR HEATED SEAT DRIVER
3 P86 20DG/YL PASSENGER SEAT TEMPERATURE SENSOR INPUT
4 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
PASSENGER HEATED SEAT SWITCH - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 P134 20TN/LG PASSENGER SEAT HEATER SWITCH MUX
2 E2 20OR PANEL LAMPS DRIVER
3 F22 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
4- -
5 Z300 20BK GROUND
6 P132 20OR/BK SEAT HEATER SWITCH SENSOR GROUND
PASSENGER LUMBAR MOTOR (MIDLINE/PREMIUM) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 P105 16LG/DG LUMBAR FORWARD SWITCH SENSE
2 P104 16YL/RD LUMBAR REARWARD SWITCH SENSE
PASSENGER LUMBAR SWITCH (MIDLINE/PREMIUM) - WHITE 6 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z1 16BK GROUND
3 P104 16YL/RD (RHD) LUMBAR REARWARD SWITCH SENSE
3 P105 16LG/DB (LHD) LUMBAR FORWARD SWITCH SENSE
4 P105 16LG/DB (RHD) LUMBAR FORWARD SWITCH SENSE
4 P104 16YL/RD (LHD) LUMBAR REARWARD SWITCH SENSE
5 Z1 16BK GROUND
6 F37 16RD/LB FUSED B(+)
8W - 80 - 104 8W-80 CONNECTOR PIN-OUTWJ

RADIATOR FAN RELAY - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 C24 20DB/PK RADIATOR FAN RELAY CONTROL
3 C23 12DG RADIATOR FAN RELAY OUTPUT
4 A16 12GY FUSED B(+)
RADIO C1 - GRAY 22 WAY
CAV CIRCUIT FUNCTION
1 F60 16RD/WT FUSED B(+)
2 X12 16WT/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
3 E2 20OR PANEL LAMPS DRIVER
4- -
5- -
6- -
7 X54 18VT RIGHT FRONT SPEAKER (+)
8 X56 18DB/PK RIGHT FRONT SPEAKER (-)
9 X55 18BR/RD LEFT FRONT SPEAKER (-)
10 X53 18DG/OR LEFT FRONT SPEAKER (+)
11 Z9 16BK GROUND
12 F60 16RD/WT FUSED B(+)
13 X64 18BR/WT ENABLE SIGNAL TO AMPLIFIER
14 D25 20YL/VT/DB PCI BUS
15 - -
16 - -
17 - -
18 X51 18WT/DG LEFT REAR SPEAKER (+)
19 X57 18DG/WT LEFT REAR SPEAKER (-)
20 X58 18DB/OR RIGHT REAR SPEAKER (-)
21 X52 18DB/WT RIGHT REAR SPEAKER (+)
22 Z9 16BK GROUND
RADIO C2 - GRAY 10 WAY
CAV CIRCUIT FUNCTION
1 X40 20WT/RD AUDIO OUT RIGHT
2 Z4 20WT/BK GROUND
3 Z5 20BK/LB SHIELD
4- -
5 X112 20RD IGNITION SWITCH OUTPUT (RUN-ACC)
6 X41 20WT/DG AUDIO OUT LEFT
7 Z17 20BK GROUND
8- -
9- -
10 X160 20YL FUSED B(+)
WJ8W-80 CONNECTOR PIN-OUT 8W - 80 - 111

SHIFTER ASSEMBLY (GAS) - WHITE 6 WAY
CAV CIRCUIT FUNCTION
1 E2 20OR PANEL LAMPS DRIVER
2 Z234 18BK GROUND
3 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
4 Z300 18BK GROUND
5 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 K29 18WT/PK SECONDARY BRAKE SWITCH SIGNAL
SHIFTER ASSEMBLY C1 (DIESEL) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
4 T2 20TN/BK BACK-UP LAMP RELAY CONTROL
5 D25 20OR PCI BUS
6 W0 20DB/WT SHIFTER C1 SENSE
7 W1 20VT/WT SHIFTER C2 SENSE
8 W2 20VT SHIFTER C3 SENSE
9 W3 20BK SHIFTER C4 SENSE
10 W4 20PK/OR SHIFTER C5 SENSE
11 Z234 20WT GROUND
12 Z234 20WT GROUND
SHIFTER ASSEMBLY C2 (DIESEL)-6WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
4 K2 20WT/PK SECONDARY BRAKE SWITCH SIGNAL
5 F991 20OR/DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 Y1 20DB/PK PARK LOCKOUT SOLENOID CONTROL
SIREN (BUILT-UP-EXPORT)-3WAY
CAV CIRCUIT FUNCTION
1 Z141 18BK GROUND
2 X75 18GY/LB (DIESEL) SIREN SIGNAL CONTROL
2 X75 18GY/LG (GAS) SIREN SIGNAL CONTROL
3 M1 18PK FUSED B(+)
SPEED CONTROL SWITCH NO. 1 - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 K4 20BK/LB SENSOR GROUND
3 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
4- -
8W - 80 - 120 8W-80 CONNECTOR PIN-OUTWJ

DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Transmission Support Bracket
ÐBolt (Manual) 46 34 Ð
Transmission Support Bracket/
CushionÐBolt (4WD Auto) 75 55 Ð
Transmission Support Adaptor
BracketÐBolts (2WD Auto) 75 55 Ð
Exhaust Manifold/PipeÐNuts 27 20 Ð
Intake/Exhaust Manifold
Fasteners #1-5 33 24 Ð
Fasteners #6 and 7 14 Ð 126
Fasteners #8-11 33 24 Ð
Flywheel to Converter
HousingÐBolts38 28 Ð
Flywheel to CrankshaftÐBolts 143 105 Ð
Front Cover to BlockÐBolts
1/4-20 7 Ð 60
5/16-18 22 Ð 192
Fuel RailÐBolts/Stud 12 Ð 108
GeneratorÐBolts 57 42 Ð
Generator Bracket to EngineÐ
Bolts47 35 Ð
Idler Pulley to Cylinder
HeadÐBolt47 35 Ð
Main Bearing CapÐBolts 108 80 Ð
Oil Filter 18 Ð 156
Oil Filter Connector to
Adaptor 47 35 Ð
Block 68 50 Ð
Adaptor Bolts 102 50 Ð
Oil GalleyÐPlug 41 30 Ð
Oil PanÐBolts
1/4-20 9.5 Ð 84
5/16-18 15 Ð 132
Oil PanÐDrain Plug 34 25 Ð
Oil Pump
Mounting Bolts 23 Ð 204
Cover Bolts 8 Ð 70
Rocker Arm Assembly to
Cylinder
HeadÐCapscrews 30 21 Ð
Spark Plugs 37 27 ÐDESCRIPTION N´m Ft. In.
Lbs. Lbs.
Starter MotorÐMounting Bolts 45 33 Ð
Thermostat HousingÐBolts 18 Ð 156
Throttle BodyÐBolts 10 Ð 90
Vibration DamperÐBolt 108 80 Ð
Water Pump to BlockÐBolts 23 17 Ð
AIR CLEANER ELEMENT
REMOVAL - 4.0L
(1) Unlatch four clips retaining air cleaner cover to
air cleaner housing (Fig. 6).
Fig. 6 Air Cleaner Assembly Ð4.0L Engine
1 - RESONATOR BOLTS
2 - CLAMPS
3 - AIR DUCT
4 - AIR CLEANER COVER
5 - CLIPS
6 - HOUSING
7 - HOUSING BOLTS (3)
8 - LOWER HOUSING NUTS (3)
9 - RESONATOR
9 - 18 ENGINE - 4.0LWJ
ENGINE - 4.0L (Continued)

AIR CLEANER HOUSING
REMOVAL - 4.7L
(1) Disconnect air cleaner cover-to-air duct clamp
(Fig. 8).
(2) Disconnect air duct at housing.
(3)Each of the 3 air cleaner housing mount-
ing bolts is attached with 2 nuts (an upper nut
and lower nut). DO NOT REMOVE BOLTS. To
prevent stripping bolts, only remove lower
nuts. The lower housing nuts are located under
left front inner fender (Fig. 8).
(a) To gain access to lower nuts, raise vehicle.
(b) Remove clips retaining rubber inner fender
shield.
(c) Pry back shield enough to gain access to
lower nuts.
(d) Remove 3 nuts.(e) Remove air cleaner assembly from vehicle.
(4) If resonator is to be removed, disconnect
breather tube at resonator, disconnect air duct clamp
at resonator (Fig. 8)and remove 2 resonator mount-
ing bolts (at sides of resonator). Remove resonator
from throttle body by loosening clamp at throttle
body.
INSTALLATION - 4.7L
(1) Position air cleaner assembly to body and
install 3 nuts. Tighten nuts to 10 N´m (93 in. lbs.)
torque.To prevent excessive vibration transmit-
ted through housing, the nuts must be properly
torqued. Do not overtighten nuts.
(2) If resonator was removed: Install resonator and
bolts. Tighten bolts to 4 N´m (35 in. lbs.) torque.
Tighten clamp at throttle body to 4 N´m (35 in. lbs.)
torque.
(3) Position fender liner and install clips.
(4) Connect air duct at housing (Fig. 8).
(5) Tighten air duct clamp.
CYLINDER HEAD - LEFT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cylinder heads are made of an aluminum alloy.
The cylinder head features two valves per cylinder
with pressed in powdered metal valve guides. The
cylinder heads also provide enclosures for the timing
chain drain, necessitating unique left and right cylin-
der heads.
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and
are pressed into the cylinder head. The guides are
not replaceable or serviceable, and valve guide ream-
ing is not recommended. If the guides are worn
beyond acceptable limits, replace the cylinder heads.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
Fig. 8 Air Cleaner Assembly - 4.7L
1 - AIR DUCT
2 - CLAMPS
3 - AIR CLEANER COVER
4 - CLIPS
5 - HOUSING
6 - HOUSING BOLTS (3)
7 - LOWER HOUSING NUTS (3)
8 - RESONATOR BOLTS
9 - RESONATOR
9 - 84 ENGINE - 4.7LWJ
AIR CLEANER ELEMENT (Continued)

DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE1. Leaks at pipe joints. 1. Tighten clamps to specified
torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).
2. Burned or blown out muffler. 2. Replace muffler assembly (Refer
to 11 - EXHAUST SYSTEM/
MUFFLER - REMOVAL). Check
exhaust system.
3. Burned or rusted-out exhaust
pipe.3. Replace exhaust pipe (Refer to
11 - EXHAUST SYSTEM/EXHAUST
PIPE - REMOVAL).
4. Exhaust pipe leaking at manifold
flange.4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).
7. Restriction in muffler or tailpipe. 7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Exhaust system contacting body
or chassis.8. Re-align exhaust system to clear
surrounding components.
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking
joints (Refer to 11 - EXHAUST
SYSTEM - SPECIFICATIONS).
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Catalytic Converter-to-
Exhaust PipeÐNuts28 Ð 250
Exhaust Pipe-to-ManifoldÐ
Nuts31 23 Ð
Heat Shield RetainingÐ
Nuts2.0 Ð 20DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Muffler-to-Catalytic
Converter
U-bolt clamp 47 35 Ð
Rear Tailpipe HangerÐ
Bolts22 Ð 192
WJEXHAUST SYSTEM 11 - 3
EXHAUST SYSTEM (Continued)

EXHAUST PIPE - 4.0L
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
(1) Raise and support the vehicle.(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 9).
(4) Remove the nuts from the exhaust pipe to cat-
alytic converter flange connection (Fig. 10).
(5) Disconnect the exhaust pipe from the exhaust
manifold (Fig. 11).
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the exhaust pipe to the engine exhaust
manifold. Tighten the nuts to 31 N´m (23 ft. lbs.)
(Fig. 11).
Fig. 9 O2 Sensor Location 4.0L
11 - 8 EXHAUST SYSTEMWJ

NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.
(2) Position the catalytic converter onto the
exhaust pipe flange connection. Tighten retaining
nuts to 28 N´m (250 in. lbs.) (Fig. 12).
(3) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
N´m (35 ft. lbs.) torque (Fig. 9).
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
(6) After initial start-up, check the engine exhaust
manifold to exhaust pipe nuts for proper torque.
Fig. 10 Catalytic ConverterÐRemoval
1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER
Fig. 11 Exhaust Pipe 4.0L
1 - NUT
2 - EXHAUST MANIFOLD
3 - TRANSMISSION SUPPORT
4 - EXHAUST PIPE
5 - MINI CATALYTIC CONVERTER
6 - BOLT
Fig. 12 Installing Exhaust Clamps
1 - CATALYTIC CONVERTER
2 - MUFFLER
WJEXHAUST SYSTEM 11 - 9
EXHAUST PIPE - 4.0L (Continued)

EXHAUST PIPE - 4.7L
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
(1) Raise and support the vehicle.(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 13).
(4) Remove the retaining nuts holding catalytic
converter to exhaust pipe (Fig. 14).
(5) Disconnect the exhaust pipe from the exhaust
manifold. (Fig. 15)
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the exhaust pipe to the engine exhaust
manifold. Tighten the nuts (A) to 31 N´m (23 ft. lbs.)
(Fig. 15).
Fig. 13 4.7L Catalytic Converter and O2 Sensor Configuration - 50 State Emissions
11 - 10 EXHAUST SYSTEMWJ