4.7 head JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

replacement is necessary, replace with the original
Mopartequipment spring type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 4).
OPERATION
OPERATIONÐCOOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It alsomaintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
OPERATIONÐHOSE CLAMPS
The worm type hose clamp uses a specified torque
value to maintain proper tension on a hose connec-
tion.
Fig. 1 Engine Cooling System 4.7L Engine
1 - LH CYL. HEAD
2 - AIR BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
7 - 2 COOLINGWJ
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
17. Viscous fan drive not operating
properly.17. Check fan drive operation and replace as
necessary. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DIAGNOSIS AND TESTING).
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING). For repair, (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
19. Heater core leaking. 19. Check heater core for leaks. (Refer to 24
- HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE - REMOVAL).
Repair as necessary.
20. Hydraulic fan speed too low or
inopertive.20. Check for
DTC code.
Check fan operation speeds.
Refer to fan speed operation table.
Low power steering pump output. Refer to
power steering pump diagnosis - 4.7L engine.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and repair if
necessary. Refer to Group 8J, Instrument
cluster.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running)3. A normal condition. No correction is
necessary. Gauge should return to normal
range after vehicle is driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction is
necessary. The gauge should return to
normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open late).5. Check and correct coolant leaks. (Refer to
7 - COOLING - DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a thermostat
to open late.6. (a) Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
WJCOOLING 7 - 7
COOLING (Continued)

STANDARD PROCEDURE - DRAINING COOLING
SYSTEM - 4.0L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(1) DO NOT remove radiator cap first. With engine
cold, raise vehicle on a hoist and locate radiator
draincock.
NOTE: Radiator draincock is located on the right/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the draincock. Put
the other end into a clean container. Open draincock
and drain coolant from radiator. This will empty the
coolant reserve/overflow tank. The coolant does not
have to be removed from the tank unless the system
is being refilled with a fresh mixture. When tank is
empty, remove radiator cap and continue draining
cooling system.
To drain the engine of coolant, remove the cylinder
block drain plug located on the side of cylinder block
(Fig. 9).
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM - 4.0L ENGINE
(1) Tighten the radiator draincock and the cylinder
block drain plug(s) (if removed).
(2) Fill system using a 50/50 mixture of ethylene-
glycol antifreeze and low mineral content water. Fill
radiator to top and install radiator cap. Add suffi-
cient coolant to the reserve/overflow tank to raise
level to FULL mark.
(3) With heater control unit in the HEAT position,
operate engine with radiator cap in place.
(4) After engine has reached normal operating
temperature, shut engine off and allow it to cool.
When engine is cooling down, coolant will be drawn
into the radiator from the reserve/overflow tank.
(5) Add coolant to reserve/overflow tank as neces-
sary.Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion.To purge the cooling system of all air,
this heat up/cool down cycle (adding coolant to cold
engine) must be performed three times. Add neces-
sary coolant to raise tank level to the FULL mark
after each cool down period.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
Fig. 8 Cooling System Bleed Plug - 4.7L
1 - COOLING SYSTEM BLEED PLUG
Fig. 9 Drain PlugÐ4.0L Engine
1 - COOLANT TEMPERATURE SENSOR
2 - BLOCK DRAIN PLUG
WJCOOLING 7 - 13
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS
REMOVAL
REMOVALÐ4.7L ENGINE...............16
REMOVALÐ4.0L ENGINE...............16
INSTALLATION
INSTALLATIONÐ4.7L ENGINE...........16
INSTALLATIONÐ4.0L ENGINE...........17
DRIVE BELTS - 4.0L
DIAGNOSIS AND TESTING ± SERPENTINE
DRIVE BELT.........................17REMOVALÐ4.0L ENGINE.................19
INSTALLATIONÐ4.0L ENGINE.............19
DRIVE BELTS - 4.7L
DIAGNOSIS AND TESTING ± SERPENTINE
DRIVE BELT.........................20
REMOVAL - 4.7L ENGINE.................22
INSTALLATION - 4.7L ENGINE.............23
BELT TENSIONERS
REMOVAL
REMOVALÐ4.7L ENGINE
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from engine front
cover (Fig. 1).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
REMOVALÐ4.0L ENGINE
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from mounting
bracket (Fig. 2).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
INSTALLATION
INSTALLATIONÐ4.7L ENGINE
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
N´m (30 ft. lbs.).
Fig. 1 Automatic Belt Tensioner
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N´m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
7 - 16 ACCESSORY DRIVEWJ

²Fan control valve
²Two stage G-rotor hydraulic drive
The hydraulic fan and drive is not serviceable.
Therefore any failure of the fan blade, hydraulic fan
drive or fan shroud requires replacement of the fan
module because the fan blade and hydraulic fan drive
are matched and balanced as a system and servicing
either separately would disrupt this balance.
For hydraulic fluid routing information refer to
(Fig. 5).
CAUTION: Do not attempt to service the hydraulic
cooling fan or fan drive separately replace the cooling
module as an assembly. Failure to do so may cause
severe damage to the hydraulic cooling fan assembly.
OPERATION
The hydraulic radiator cooling fan used on the
Grand Cherokee with the 4.7L engine replaces both
the electric fan and the engine driven mechanical
fan. The use of this hydraulic fan provides the 4.7L
equipped Grand Cherokee with heavy trailer tow
capability while at the same time reducing unneces-
sary power drain on both the engine and the vehicles
electrical system.
HYDRAULIC FAN STRATEGY
The hydraulic radiator cooling fan is controlled by
the JTEC. A PWM (Pulse With Modulated) signal
from the JTEC controls the fan from 0 to 100% of the
available fan speed. There are four inputs to the
JTEC that determine what speed percentage of fan is
required by the vehicle. These inputs are:
²Engine Coolant Temperature
²Transmission Oil Temperature
²Battery Temperature
²A/C System Pressure
By monitoring these four parameters, the JTEC
can determine if cooling airflow is required. If airflow
is required, the JTEC will slowly ramp up (speed up)
the fan speed until the parameter(s) are under con-
trol. Once the temperature or pressure is reduced to
within operating parameters the fan will ramp up,
ramp down, or hold its speed to maintain the temper-
ature / pressure requirements.
NOTE: Even if the JTEC is not requesting fan on
operation the fan blade will usually spin between
100 and 500 RPM when the vehicle is at idle. This is
due to a controlled minimum oil flow requirement
through the fan drive motor.
ACTIVATING THE HYDRAULIC FAN WITH THE DRB
Under the Engine Systems test heading, there is a
subheading. ªHydraulic fan solenoid testº, that has
the selections, on /off. Activating the fan with the
DRB will run the fan at 100% duty cycle, which will
help troubleshoot any system problems, and also help
with the deaeration procedure.
NOTE: Engine must be running to activate the fan
with the DRB.
RADIATOR COOLING FAN HYDRAULIC FLUID PATH
Hydraulic fluid is pumped through the power
steering pump, from the pump the fluid travels
though a high pressure delivery line to the fan drive
motor. As fluid is diverted through the G-rotors, rota-
tional motion is created as fluid moves from the high-
pressure (inlet) side of the motor to the low-pressure
(outlet) side. Fluid exiting the drive motor is divided
into two paths. Path one continues through a high
pressure delivery line to the vehicles steering gear to
provide steering assist. and path two sends fluid
back to the power steering pump through a low pres-
sure line. Fluid exits the steering gear under low
pressure and travels through a low pressure line to
the power steering fluid cooler to be cooled before
being returned back the the power steering fluid res-
ervoir (Fig. 5).
Fig. 4 HYDRAULIC RADIATOR COOLING FAN AND
FAN DRIVE
1 - POWER STEERING FLUID COOLER
2 - RADIATOR
3 - HIGH PRESSURE LINE FROM STEERING GEAR PUMP TO
HYDRAULIC FAN MOTOR
4 - HYDRAULIC FAN MOTOR
5 - HIGH PRESSURE LINE FROM HYDRAULIC FAN MOTOR TO
STEERING GEAR
6 - FAN SHROUD
7 - 28 ENGINEWJ
RADIATOR FAN - 4.7L (Continued)

REMOVAL
REMOVALÐ4.0L ENGINE
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing (Refer to 7 -
COOLING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(2) Remove radiator upper hose and heater hose at
thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 24).
Discard old gasket.
(5) Clean the gasket mating surfaces.
REMOVALÐ4.7L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Remove splash shield.(5) Remove lower radiator hose clamp and lower
radiator hose at thermostat housing.
(6) Remove thermostat housing mounting bolts,
thermostat housing and thermostat (Fig. 25).
INSTALLATION
INSTALLATIONÐ4.0L ENGINE
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl-
inder head (Fig. 26).
(b) Position thermostat in groove with arrow and
air bleed hole on outer flange pointing up.
(2) Install replacement gasket and thermostat
housing.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess,
may result in a cracked housing.
(3) Tighten the housing bolts to 22 N´m (16 ft. lbs.)
torque.
(4) Install hoses to thermostat housing.
Fig. 24 Thermostat
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT
7 - 38 ENGINEWJ
ENGINE COOLANT THERMOSTAT (Continued)

(4) Disconnect the instrument panel wire harness
connectors and the antenna coaxial cable connector
from the receptacles on the rear of the radio receiver.
(5) Remove the radio receiver from the instrument
panel.
INSTALLATION
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the radio receiver to the instrument
panel.
(2) Reconnect the instrument panel wire harness
connectors and the antenna coaxial cable connector
to the receptacles on the rear of the radio receiver.
(3) Install the four mounting screws. Tighten the
screws to 2.2 N´m (20 in. lbs.).(4) Install the center upper bezel onto the instru-
ment panel. (Refer to 23 - BODY/INSTRUMENT
PANEL - INSTALLATION) for the procedures.
(5) Reconnect the battery negative cable.
RADIO NOISE SUPPRESSION
GROUND STRAP
DESCRIPTION
Radio Frequency Interference (RFI) and Electro-
Magnetic Interference (EMI) noise suppression is
accomplished primarily through circuitry internal to
the radio receivers. These internal suppression
devices are only serviced as part of the radio receiver.
External suppression devices that are used on this
vehicle to control RFI or EMI noise include the fol-
lowing:
²Radio antenna base ground
²Radio receiver chassis ground wire or strap
²Engine-to-body ground strap(s)
²Exhaust system-to-body and transmission
ground strap (4.7L engines only)
²Resistor-type spark plugs
²Radio suppression-type secondary ignition wir-
ing.
For more information on the spark plugs and sec-
ondary ignition components, refer to Ignition System
in Ignition System.
REMOVAL
REMOVAL - ENGINE-TO-BODY GROUND
STRAP
(1) Remove the screw that secures the engine-to-
body ground strap eyelet to the lower plenum panel
(Fig. 13) or (Fig. 14).
(2) On models with a 4.0L engine, remove the nut
that secures the engine-to-body ground strap eyelet
to the stud on the right rear side of the engine cyl-
inder head.
(3) On models with a 4.7L engine, remove the two
nuts that secure the engine-to-body ground strap eye-
lets to the studs on the right and left rear sides of
the engine intake manifold.
(4) Remove the engine-to-body ground strap eye-
let(s) from the stud(s) on the engine.
(5) Remove the engine-to-body ground strap from
the engine compartment.
Fig. 12 Radio Remove/Install
1 - INSTRUMENT PANEL
2 - SCREW (4)
3 - RADIO RECEIVER
8A - 18 AUDIOWJ
RADIO (Continued)

REMOVAL - EXHAUST-TO-BODY GROUND
STRAP
(1) Raise and support vehicle.
(2) Remove fasteners from exhaust, crossmember
and transmission/transfer case.
(3) Remove the ground strap.
INSTALLATION
INSTALLATION - ENGINE TO BODY GROUND
STRAP
(1) Position the engine-to-body ground strap into
the engine compartment.
(2) Install the engine-to-body ground strap eye-
let(s) onto the stud(s) on the engine.
(3) On models with a 4.0L engine, install and
tighten the nut that secures the engine-to-body
ground strap eyelet to the stud on the right rear side
of the engine cylinder head. Tighten the nut to 5.6
N´m (50 in. lbs.).
(4) On models with a 4.7L engine, install and
tighten the two nuts that secure the engine-to-body
ground strap eyelets to the studs on the right and
left rear sides of the engine intake manifold. Tighten
the nuts to 11.3 N´m (100 in. lbs.).(5) Install and tighten the screw that secures the
engine-to-body ground strap eyelet to the lower ple-
num panel. Tighten the screw to 4.5 N´m (40 in. lbs.).
INSTALLATION - EXHAUST-TO-BODY GROUND
STRAP
(1) Install the ground strap to the exhaust, cross-
member and transmission/transfer case.
(2) Install the fasteners.
(3) Lower the vehicle.
REMOTE SWITCHES
DESCRIPTION
Remote radio control switches are included on
models equipped with the optional leather-wrapped
steering wheel. The two rocker-type switch units
(Fig. 15) are mounted in the upper spoke covers of
the rear (instrument panel side) steering wheel trim
cover. The switch unit on the left side is the seek
switch and has seek up, seek down, and preset sta-
tion advance switch functions. The switch unit on the
right side is the volume control switch and has vol-
ume up, volume down, and mode advance switch
functions.
Fig. 13 Engine-To-Body Ground Strap Remove/
Install - 4.0L Engine
1 - SCREW
2 - LOWER PLENUM PANEL
3 - ENGINE
4 - STUD
5 - NUT
6 - GROUND STRAP
Fig. 14 Engine-To-Body Ground Strap Remove/
Install - 4.7L Engine
1 - GROUND STRAP
2 - SCREW
3 - ENGINE
4 - STUD (2)
5 - NUT (2)
6 - LOWER PLENUM PANEL
WJAUDIO 8A - 19
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)

(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.
(6) Unlatch and open the cover on the Power Dis-
tribution Center (PDC).
(7) Remove the two nuts that secure the battery
positive cable and generator output cable eyelet ter-
minal to the B(+) terminal studs in the PDC.
(8) Remove the battery positive cable and genera-
tor output cable eyelet terminal from the B(+) termi-
nal studs in the PDC.
(9) Disconnect the battery wire harness connector
from the right headlamp and dash wire harness con-
nector located near the front of the battery.
(10) Remove the screw that secures the battery
negative cable eyelet terminal to the inner fender
shield near the front of the battery.
(11) On models with the 4.7L engine, remove the
nut that secures the battery harness clip to the stud
on the right side of the intake manifold and remove
the clip from the stud.
(12) Unlatch and remove the cover from the gener-
ator output terminal stud housing on the back of the
generator.
(13) Remove the nut that secures the generator
output cable eyelet terminal to the generator output
terminal stud.
(14) Remove the generator output cable eyelet ter-
minal from the generator output terminal stud.
(15) Disconnect the battery wire harness connector
from the generator field terminal connector recepta-
cle on the back of the generator.(16) Remove the screw that secures the battery
negative cable ground eyelet terminal to the right
side of the engine block.
(17) Remove the nut that secures the battery pos-
itive cable eyelet terminal to the B(+) terminal stud
on the starter solenoid.
(18) Remove the battery positive cable eyelet ter-
minal from the B(+) terminal stud on the starter
solenoid.
(19) Disconnect the battery wire harness connector
from the connector receptacle on the starter solenoid.
(20) Remove the battery wire harness from the
engine compartment.
INSTALLATION
Both the battery negative cable and the battery
positive cable are serviced in the battery wire har-
ness. If either battery cable is damaged or faulty, the
battery wire harness unit must be replaced.
(1) Clean and inspect the battery cable terminal
clamps and the battery terminal posts.
(2) Position the battery wire harness into the
engine compartment (Fig. 23) or (Fig. 24).
(3) Reconnect the battery wire harness connector
to the connector receptacle on the starter solenoid.
(4) Install the battery positive cable eyelet termi-
nal onto the B(+) terminal stud on the starter sole-
noid.Fig. 22 TEST GROUND CIRCUIT RESISTANCE -
TYPICAL
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 23 Battery Cables - 4.0L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
8F - 20 BATTERY SYSTEMWJ
BATTERY CABLE (Continued)

(5) Install and tighten the nut that secures the
battery positive cable eyelet terminal to the B(+) ter-
minal stud on the starter solenoid. Tighten the nut to
11.3 N´m (100 in. lbs.).
(6) Install and tighten the screw that secures the
battery negative cable ground eyelet terminal to the
right side of the engine block. Tighten the screw to
10.2 N´m (90 in. lbs.) for 4.0L engines, or 13.0 N´m
(115 in. lbs.) for 4.7L engines.
(7) Reconnect the battery wire harness connector
to the generator field terminal connector receptacle
on the back of the generator.
(8) Install the generator output cable eyelet termi-
nal onto the generator output terminal stud.
(9) Install and tighten the nut that secures the
generator output cable eyelet terminal to the genera-
tor output terminal stud. Tighten the nut to 10.7
N´m (95 in. lbs.).
(10) Position the cover for the generator output
terminal stud housing onto the back of the generator
and snap it into place.
(11) On models with the 4.7L engine, install the
battery harness clip onto the stud on the right side of
the intake manifold, then install and tighten the nut
that secures the clip to the stud. Tighten the nut to
11.3 N´m (100 in. lbs.).
(12) Install and tighten the screw that secures the
battery negative cable eyelet terminal to the inner
fender shield near the front of the battery. Tighten
the screw to 28.2 N´m (250 in. lbs.).(13) Reconnect the battery wire harness connector
to the right headlamp and dash wire harness connec-
tor located near the front of the battery.
(14) Install the battery positive cable and genera-
tor output cable eyelet terminal onto the PDC B(+)
terminal studs.
(15) Install and tighten the two nuts that secure
the battery positive cable and generator output cable
eyelet terminal to the PDC B(+) terminal studs.
Tighten the nuts to 11.3 N´m (100 in. lbs.).
(16) Close and latch the PDC cover.
(17) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 6.8 N´m (60
in. lbs.).
(18) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 6.8 N´m (60
in. lbs.).
(19) Apply a thin coating of petroleum jelly or
chassis grease to the exposed surfaces of the battery
cable terminal clamps and the battery terminal
posts.BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic battery
tray and support unit (Fig. 25) located in the right
front corner of the engine compartment. The battery
tray and support unit is secured at the rear with a
nut to a stud on the front wheelhouse inner panel, at
the outboard side with a screw to the side cowl rein-
forcement panel, and at the front with a screw
through a U-nut on a bracket of the radiator support.
The battery tray and support unit also includes
three upright stanchions that are molded into the
outboard side of the unit. These stanchions support
the Power Distribution Center (PDC). Refer to
Power Distribution Centerin the Power Distribu-
tion section of this service manual for more informa-
tion on the PDC.
A hole in the bottom of the battery tray is fitted
with a battery temperature sensor. Refer toBattery
Temperature Sensorin the Charging section of
this service manual for more information on the bat-
tery temperature sensor. Refer toBattery Hold
Downin this section of the service manual for more
information on the battery hold down hardware.
Fig. 24 Battery Cables - 4.7L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
WJBATTERY SYSTEM 8F - 21
BATTERY CABLE (Continued)