hood open JEEP GRAND CHEROKEE 2002 WJ / 2.G Owner's Manual

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Fuel Pump Module (Gas) BK Near Fuel Tank 33, 35
Fuel Tank Module Diesel) BK Near Fuel Tank 33, 35
Generator (Diesel) LTGY At Generator 8
Generator (Gas) BK At Generator N/S
Glove Box Lamp BK Inside Glove Box 19, 20, 22
Headlamp Leveling Switch
(Built-Up-Export)WT Driver Side of Instrument Panel 20
Hood Ajar Switch BK Left Side of Engine Compartment 3, 4
Horn No.1 BK Right Front Fascia 5
Horn No.2 BK Right Front Fascia 5
Hydraulic Cooling Module BK Right Front of Engine Compartment 5
Idle Air Control Motor BK Left Side of Engine Near Throttle
Body13
Ignition Switch - C1 WT On Steering Column 23
Ignition Switch - C2 BK On Steering Column 23
Input Speed Sensor (4.7L) BK Left Side of Transmission 16
Instrument Cluster WT At Instrument Cluster 19, 20
Intake Air Temperature Sensor
(Gas)GY Left Side of Engine 9, 13
Intake Air Temperature Sensor
(Diesel)BK Near T/O for Crankcase Heater 8
Intake Port Swirl Actuator
(Diesel)BK Right Rear of Engine Compartment N/S
Intrusion Transceiver Module
(Built-up-Export)BK In The Overhead N/S
Junction Block - C1 BK At Junction Block 30, 31, 33
Junction Block - C2 BK At Junction Block 30, 31
Junction Block - C3 BK At Junction Block 21, 22, 30
Junction Block - C4 WT At Junction Block 30, 31
Junction Block - C5 WT At Junction Block 30, 31
Knock Sensor (4.7L High
Output)BK Right Rear Side of Engine, Near
Coil on Plug No.8N/S
Leak Detection Pump (Except
Built-Up-Export)Left Front Wheel Opening 3
Left Courtesy Lamp BK Left Side of Instrument Panel 21 22, 23
Left Curtain Airbag BK Near Left C Pillar 37
Left Door Handle Courtesy
LampBK At Lamp N/S
Left Fog Lamp BK At Lamp 3, 4
Left Front Door Speaker WT In Left Front Door 24, 27
Left Front Impact Sensor BK Left Front Frame Near Windshield
Washer Pump3, 4
Left Front Park Lamp WT At Lamp N/S
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DIAGNOSIS AND TESTING
WATER LEAKS........................1
WIND NOISE..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................2
STANDARD PROCEDURE - DRILLING AND
WELDING............................3
SPECIFICATIONS
BODY LUBRICANTS....................3
SPECIFICATIONS - TORQUE.............4
SPECIAL TOOLS
BODY...............................4DECKLID/HATCH/LIFTGATE/TAILGATE........5
DOOR - FRONT.........................11
DOORS - REAR.........................19
EXTERIOR.............................25
HOOD.................................33
INSTRUMENT PANEL SYSTEM.............36
INTERIOR..............................69
PAINT.................................81
SEATS................................83
STATIONARY GLASS.....................93
SUNROOF.............................96
WEATHERSTRIP/SEALS..................105
BODY STRUCTURE.....................112
BODY
DIAGNOSIS AND TESTING
WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
WJBODY 23 - 1

EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Apply a length of masking tape on the body,
parallel to the top edge of the nameplate to use as a
guide, if necessary.
(2) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun. Do not exceed 52ÉC
(120ÉF) when heating emblem.
(3) Insert a plastic trim stick or a hard wood
wedge behind the emblem to separate the adhesive
backing from the body.
(4) Clean adhesive residue from body with MOPAR
Super Clean solvent or equivalent.
INSTALLATION
(1) Remove protective cover from adhesive tape on
back of emblem.
(2) Position emblem properly on body.(3) Press emblem firmly to body with palm of
hand.
(4) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun to assure adhesion.
Do not exceed 52ÉC (120ÉF) when heating emblem.
FRONT FENDER
REMOVAL
(1) Using a wax crayon or equivalent, mark posi-
tion of fender.
(2) Remove front fender liner.
(3) Pull back fascia and remove screws attaching
fender to fascia.
(4) Remove screws attaching lower fender bracket
located behind fascia.
(5) Remove screws attaching fender to rocker
panel (Fig. 6).
(6) Remove screws attaching rear of fender to
A-pillar brackets.
(7) Open hood.
Fig. 6 Fender Mounting
1 - BODY
2 - FENDER
23 - 28 EXTERIORWJ

(8) Loosen screw under hood hinge, attaching
fender to engine compartment rail.
(9) Remove screws attaching fender to engine com-
partment rail (Fig. 7).
(10) Right fender only:
(a) If equipped, remove radio antenna.
(11) Separate fender from body.
INSTALLATION
(1) Position fender on body.
(2) Right fender only:
(a) If equipped, install radio antenna.
(3) Install all screws finger-tight.
(4) Align fender with adjacent body panels and
wax crayon reference marks.
(5) Tighten all screws.
(6) Install inner fender liner.
FUEL FILL DOOR
REMOVAL
(1) Open the fuel filler door.
(2) Remove the screws attaching the door to the
quarter panel (Fig. 8).
(3) Remove the door from the panel.
INSTALLATION
(1) Position the fuel filler door on the quarter
panel with the screw holes aligned.(2) Install the screws attaching the fuel filler door
to the quarter panel.
GRILLE
REMOVAL
(1) Remove fascia, refer to (Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT FASCIA - REMOV-
AL).
(2) Disengage retainers attaching grille insert to
grille/fascia.
(3) Separate grille insert from grille/fascia (Fig. 9).
INSTALLATION
(1) Position grille insert in grille/fascia (Fig. 9).
(2) Engage retainers attaching grille insert to
grille/fascia.
Fig. 7 Upper Fender Mounting
1 - FENDER
2 - BODY
Fig. 8 Fuel Filler Door
1 - FUEL FILL DOOR
Fig. 9 Grille Insert
1 - GRILLE/FASCIA
2 - INSERT
WJEXTERIOR 23 - 29
FRONT FENDER (Continued)

HOOD
TABLE OF CONTENTS
page page
GAS PROP
REMOVAL.............................33
INSTALLATION.........................33
HINGE
REMOVAL.............................33
INSTALLATION.........................33
HOOD
REMOVAL.............................33
INSTALLATION.........................34
ADJUSTMENTS
HOOD ADJUSTMENT..................34INSULATION
REMOVAL.............................34
INSTALLATION.........................34
LATCH
REMOVAL.............................34
INSTALLATION.........................34
LATCH RELEASE CABLE
REMOVAL.............................35
INSTALLATION.........................35
GAS PROP
REMOVAL
(1) Raise and support hood.
(2) Using a small flat blade, pry the retainer
attaching hood support prop to lower ball stud.
(3) Slide retainer attaching hood support prop
upper ball stud downward.
(4) Disconnect hood support prop from lower ball
stud and rotate support prop upward and disconnect
from upper ball stud (Fig. 1).
INSTALLATION
(1) Position hood support prop on upper ball stud
(Fig. 1).(2) Slide retainer upward to secure support prop to
upper ball stud.
(3) Position support prop on lower ball stud and
press retainer inward to secure.
HINGE
REMOVAL
(1) Raise and support hood.
(2) Using a wax crayon or equivalent, mark posi-
tion of hinge.
(3) Remove hood hinge prop rod.
(4) Remove nuts attaching hinge to hood (Fig. 1).
(5) Remove bolts attaching hinge to body.
(6) Separate hinge from vehicle.
INSTALLATION
(1) Position hinge on vehicle and align reference
marks.
(2) Install bolts attaching hinge to body.
(3) Install nuts attaching hinge to hood.
(4) Install hood hinge prop rod.
HOOD
REMOVAL
(1) Raise hood.
(2) If equipped, disconnect underhood lamp har-
ness connector. (Connector is located under cowl
cover).
(3) Using a wax crayon or equivalent, mark loca-
tion of hood hinges on hood for installation align-
ment.
(4) Support hood in the open position.
(5) Remove hood support prop rods.
Fig. 1 Hood Support Prop
1 - HOOD
2 - COVER
3 - HINGE
4 - PROP
WJHOOD 23 - 33

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
B-PILLAR DOOR SEAL
REMOVAL............................105
INSTALLATION........................105
COWL WEATHERSTRIP
REMOVAL............................106
INSTALLATION........................106
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL............................106
INSTALLATION........................106
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL............................106
INSTALLATION........................107
FDR OUTER BELT WEATHERSTRIP
REMOVAL............................107
INSTALLATION........................107
FLIP-UP GLASS WEATHERSTRIP
REMOVAL............................107
INSTALLATION........................107
FRONT DOOR 2ND WEATHERSTRIP
REMOVAL............................107
INSTALLATION........................107
FRONT DOOR WEATHERSTRIP
REMOVAL............................108INSTALLATION........................108
HOOD SEAL
REMOVAL............................108
INSTALLATION........................108
LIFTGATE OPENING WEATHERSTRIP
REMOVAL............................109
INSTALLATION........................109
RDR INNER BELT WEATHERSTRIP
REMOVAL............................109
INSTALLATION........................109
RDR OUTER BELT WEATHERSTRIP
REMOVAL............................109
INSTALLATION........................109
RDR SECONDARY WEATHERSTRIP
REMOVAL............................110
INSTALLATION........................110
REAR DOOR WEATHERSTRIP
REMOVAL............................110
INSTALLATION........................110
ROOF RAIL WEATHERSTRIP / RETAINR
REMOVAL............................110
INSTALLATION........................110
B-PILLAR DOOR SEAL
REMOVAL
The B-pillar seal is attached to the rear door with
adhesive tape.
(1) Peel seal from the door (Fig. 1).
INSTALLATION
(1) Clean contact area with MopartSuper Kleen
or equivalent.
(2) Remove carrier from seal.
(3) Align seal on door and press into place.
Fig. 1 B-Pillar Seal
1 - B-PILLAR SEAL
WJWEATHERSTRIP/SEALS 23 - 105

FRONT DOOR WEATHERSTRIP
REMOVAL
(1) Remove A-pillar trim (Refer to 23 - BODY/IN-
TERIOR/A-PILLAR TRIM - REMOVAL).
(2) Remove B-pillar upper trim (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
REMOVAL).
(3) Remove B-pillar lower trim (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL).
(4) Pull weatherstrip from door opening flange.
INSTALLATION
(1) Position weatherstrip at corners.
(2) Move upward and around edge of door opening
seating weatherstrip onto flange (Fig. 7).
(3) Engage connector plug with each end of weath-
erstrip at bottom of door opening.
(4) Install B-pillar lower trim (Refer to 23 - BODY/
INTERIOR/B-PILLAR LOWER TRIM - INSTALLA-
TION).
(5) Install B-pillar upper trim (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION).
(6) Install A-pillar trim (Refer to 23 - BODY/INTE-
RIOR/A-PILLAR TRIM - INSTALLATION).
HOOD SEAL
REMOVAL
(1) Raise hood.
(2) Pull hood seal from upper radiator crossmem-
ber.
(3) Separate seal from upper radiator crossmember
(Fig. 8).
INSTALLATION
(1) Position seal on upper radiator crossmember.
(2) Press seal onto upper radiator crossmember to
seat.
Fig. 7 Door Opening
1 - REAR DOOR OPENING WEATHERSTRIP
2 - FRONT DOOR OPENING WEATHERSTRIP
Fig. 8 Hood Seal
1 - HOOD SEAL
23 - 108 WEATHERSTRIP/SEALSWJ

STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
(9) Connect the negative battery cable.
A/C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radia-
tor or condenser service.
The condenser cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Remove the screws attaching the grille and
headlamp mounting module to the upper crossmem-
ber of the vehicle. Refer to Body for this and further
steps in the procedure.
(4) Remove the headlamps from their mounts.
(5) Remove the nuts that secure the hood latch
and brace to the upper crossmember.
(6) The radiator upper crossmember can be
adjusted left or right through the use of its slotted
mounting holes. Before removal, mark the original
position of the crossmember.
(7) Remove the bolts that secure the radiator to
the upper crossmember and set it aside (Fig. 6).
(8) Remove the engine air filter inlet duct secured
at the headlamp mounting module.
(9) Remove the headlamp mounting module and
front fascia for access to the condenser and fittings.
(10) Disconnect the discharge line and liquid line
refrigerant line fittings from the condenser. Install
plugs in, or tape over all of the opened refrigerant
line fittings.Fig. 6 CONDENSER MOUNTING - TYPICAL
1 - CONDENSER-TO-RADIATOR MOUNTING BRACKETS (2)
2 - UPPER CROSSMEMBER
3 - FAN SHROUD
4 - ALIGNMENT TABS
5 - RADIATOR
6 - ALIGNMENT DOWELS (2)
7 - RUBBER ISOLATORS (2)
8 - RUBBER GROMMETS (2)
9 - LOWER CROSSMEMBER
10 - CONDENSER
24 - 62 PLUMBINGWJ
A/C COMPRESSOR (Continued)