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

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION..........................1
FASTENER IDENTIFICATION
DESCRIPTION..........................1
FASTENER USAGE
DESCRIPTION - FASTENER USAGE.........4
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR....4
INTERNATIONAL SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS . . . 4
METRIC SYSTEM
DESCRIPTION..........................5TORQUE REFERENCES
DESCRIPTION..........................7
VEHICLE EMISSION CONTROL INFORMATION
(VECI)
DESCRIPTION..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION..........................8
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION..........................9
BODY CODE PLATE
DESCRIPTION
A metal Body Code plate is located in the engine
compartment and attached to the top of the right
frame rail. The information listed on the plate (Fig.
1) is used for manufacturing and service purposes.
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. 2) and (Fig. 3).
Fig. 1 Body Code Plate
WJINTRODUCTION 1

FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL 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.
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
INTERNATIONAL 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 INTRODUCTIONWJ

METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
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 (60É 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 to convert
torque values listed in metric Newton- meters (N´m).
Also, use the chart to convert between millimeters
(mm) and inches (in.) (Fig. 4).
WJINTRODUCTION 5

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-tions Chart for torque references not listed in the
individual torque charts (Fig. 5).
Fig. 5 TORQUE SPECIFICATIONS
WJINTRODUCTION 7

WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION..........................3
OPERATION............................3
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER.......3STANDARD PROCEDURE - CASTER.......4
STANDARD PROCEDURE - TOE POSITION . . 4
SPECIFICATIONS
ALIGNMENT..........................5
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe position (Fig. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated, Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
²CASTERis the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
top of the knuckle forward provides negative caster.
Caster is a directional stability angle. This angle
enables the front wheels to return to a straight
ahead position after turns (Fig. 1).
²CAMBERis the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on theinside or outside edge of the tire. The angle is not
adjustable, damaged component(s) must be replaced
to correct the camber angle (Fig. 1).
²WHEEL TOE POSITIONis the difference
between the leading inside edges and trailing inside
edges of the front tires. Incorrect wheel toe position
is the most common cause of unstable steering and
uneven tire wear. The wheel toe position is thefinal
front wheel alignment adjustment (Fig. 1).
²STEERING AXIS INCLINATION ANGLEis
measured in degrees and is the angle that the steer-
ing knuckles are tilted. The inclination angle has a
fixed relationship with the camber angle. It will not
change except when a spindle or ball stud is dam-
aged or bent. The angle is not adjustable, damaged
component(s) must be replaced to correct the steering
axis inclination angle.
²THRUST ANGLEis the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle (Fig. 1).
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER
Before each alignment reading the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down three times. Always release the bumper in the
down position.
To obtain an accurate alignment, a 4 wheel align-
ment machine must be used and the equipment cali-
bration verified.
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered.
WJWHEEL ALIGNMENT 2 - 3

FRONT
TABLE OF CONTENTS
page page
FRONT
DESCRIPTION..........................6
STANDARD PROCEDURE - SERVICE
WARNINGS AND CAUTIONS..............6
SPECIFICATIONS
TORQUE CHART......................7
SPECIAL TOOLS
FRONT SUSPENSION...................8
BUSHINGS
REMOVAL.............................9
INSTALLATION..........................9
HUB / BEARING
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................9
INSTALLATION.........................10
KNUCKLE
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL - STEERING KNUCKLE..........10
INSTALLATION.........................10
LOWER BALL JOINT
REMOVAL.............................11
LOWER CONTROL ARM
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11SHOCK
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................12
SPRING
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................13
STABILIZER BAR
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
TRACK BAR
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
UPPER BALL JOINT
REMOVAL.............................15
UPPER CONTROL ARM
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
FRONT
DESCRIPTION
The front suspension (Fig. 1) is a link/coil design
comprised of :
²Drive axle
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Track bar
²Jounce bumpers
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.CAUTION: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
STANDARD PROCEDURE - SERVICE
WARNINGS AND CAUTIONS
CAUTION: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
2 - 6 FRONTWJ

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 35 26 Ð
Shock Absorber Lower Nut 28 Ð 250
Suspension Arm Upper Axle Bracket Nut 61 45 Ð
Suspension Arm Upper Frame Bracket Bolt 61 45 Ð
Suspension Arm Lower Axle Bracket Nut 163 120 Ð
Suspension Arm Lower Frame Bracket Bolt 156 115 Ð
Stabilizer Bar Retainer Bolts 92 68 Ð
Stabilizer Bar Link Upper Nut 106 78 Ð
Stabilizer Bar Link Lower Nut 106 78 Ð
Track Bar Frame Bracket Nut 108 80 Ð
Track Bar Axle Bracket Bolt 100 74 Ð
Hub Bearing Knuckle Bolts 102 75 Ð
Fig. 1 Front
1 - SHOCK
2 - COIL SPRING
3 - UPPER SUSPENSION ARM
4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
WJFRONT 2 - 7
FRONT (Continued)

ing (Fig. 4) from the steering knuckle and off the
axle shaft.
INSTALLATION
(1) Install the hub bearing to the knuckle.
(2) Install the hub bearing to knuckle bolts and
tighten to 102 N´m (75 ft. lbs.).
(3) Install the hub washer and nut. Tighten the
hub nut to 237 N´m (175 ft. lbs.). Install the nut
retainer and a new cotter pin.
(4) Install the brake rotor, caliper anchor, caliper
and ABS wheel speed sensor,(Refer to 5 - BRAKES/
ELECTRICAL/FRONT WHEEL SPEED SENSOR -
INSTALLATION).
(5) Install the wheel and tire assembly (Refer to 22
- TIRES/WHEELS - STANDARD PROCEDURE).
(6) Remove the support and lower the vehicle.
KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
REMOVAL - STEERING KNUCKLE
Ball stud service procedures below require removal
of the hub bearing and axle shaft. Removal andinstallation of upper and lower ball studs require the
use of Tool Kit 6289.
(1) Remove hub bearing and axle shaft.
(2) Disconnect the tie-rod or drag link from the
steering knuckle arm,(Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL) .
(3) Remove the cotter pins from the upper and
lower ball studs.
(4) Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen knuckle from the ball studs. Remove
knuckle from ball studs (Fig. 5).
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten the bottom retaining nut to
109 N´m (80 ft. lbs.) torque. Install new cotter pin.
(3) Install and tighten the top retaining nut to 101
N´m (75 ft. lbs.) torque. Install new cotter pin.
(4) Install the hub bearing and axle shaft.
(5) Connect the tie-rod or drag link end to the
steering knuckle arm.,(Refer to 19 - STEERING/
LINKAGE/TIE ROD END - INSTALLATION) .
Fig. 4 Hub Bearing & Knuckle
1 - HUB BEARING
2 - KNUCKLE
Fig. 5 Steering Knuckle Removal/Installation
1 - AXLE YOKE
2 - UPPER BALL STUD
3 - LOWER BALL STUD
4 - STEERING KNUCKLE
2 - 10 FRONTWJ
HUB / BEARING (Continued)

(6) Install the track bar to the axle bracket and
install the mounting bolt.
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar bolt.
(7) Remove the hydraulic jack from under the
vehicle.
(8) Tighten all suspension components to proper
torque.
(9) Install the wheel and tire assemblies.
(10) Remove support and lower vehicle.
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and is mounted to the frame rails. Links are
connected from the bar to the axle brackets. The sta-
bilizer bar and links are isolated by rubber bushings.
OPERATION
The stabilizer bar is used to control vehicle body
roll during turns. The spring steel bar helps to con-
trol the vehicle body in relationship to the suspen-
sion.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove link nuts and bolts (Fig. 13) and
remove the links.
(3) Remove the stabilizer bar retainer bolts (Fig.
13)from the frame rails and remove the stabilizer
bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the retainers and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 92 N´m (68 ft. lbs.).
(2) Install the links onto the stabilizer bar and
axle brackets and install the bolts and nuts finger
tight.
(3) Remove the supports and lower the vehicle.
(4) With the vehicle on the ground tighten the sta-
bilizer bar link nuts to 106 N´m (78 ft. lbs.).
TRACK BAR
DESCRIPTION
The bar is attached to a frame rail bracket and
axle bracket. The bar is forged and has non replace-
able isolator bushings at both ends.
OPERATION
The track bar is used to control front axle lateral
movement and provides cross car location of the axle
assembly.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the nut and bolt from the frame rail
bracket (Fig. 14).
(3) Remove the bolt from the axle shaft tube
bracket (Fig. 15). Remove the track bar.
INSTALLATION
(1) Install the track bar to the axle tube bracket.
Install the retaining bolt finger tight.
Fig. 13 Stabilizer Bar
1 - LINK
2 - STABILIZER BAR
3 - BUSHING
4 - RETAINER
Fig. 14 Track Bar Frame Rail Bracket
1 - FRAME RAIL
2 - TRACK BAR
2 - 14 FRONTWJ
SPRING (Continued)

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION.........................17
WARNING.............................17
DIAGNOSIS AND TESTING - REAR
SUSPENSION........................18
SPECIFICATIONS
TORQUE CHART......................18
SPECIAL TOOLS
REAR SUSPENSION...................19
LOWER CONTROL ARM
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
SHOCK
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
SPRING
DESCRIPTION.........................20OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
STABILIZER BAR
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
UPPER BALL JOINT
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............21
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............21
REMOVAL.............................21
INSTALLATION.........................22
UPPER CONTROL ARM
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
REAR
DESCRIPTION
The rear suspension (Fig. 1) is comprised of :
²Drive axle
²Shock absorbers
²Coil springs
²Lower suspension arms
²Upper suspension arm
²Stabilizer bar
CAUTION: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear.
WARNING
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normalride position, vehicle ride comfort will be affected
and cause premature bushing wear.
Fig. 1 Rear Suspension
1 - SHOCK
2 - UPPER SUSPENSION ARM
3 - COIL SPRING
4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
WJREAR 2 - 17