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

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Driveline
5Brakes
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Service Manual Comment Forms (Rear of 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

VEHICLE EMISSION CONTROL
INFORMATION (VECI)
DESCRIPTION
All vehicles are equipped with a combined vehicle
emission control information (VECI) label(s). The
label is located in the engine compartment on the
vehicle hood (Fig. 6). Two labels are used for vehicles
built for sale in the country of Canada.
The VECI label(s) contain the following:
²Engine family and displacement
²Evaporative family
²Emission control system schematic
²Certification application
²Spark plug and gap
The label also contains an engine vacuum sche-
matic. There are unique labels for vehicles built for
sale in the state of California and the country of
Canada. Canadian labels are written in both the
English and French languages. These labels are per-
manently attached and cannot be removed without
defacing information and destroying label.
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line X = Grand Cherokee 4X2 (LHD)
W = Grand Cherokee 4X4 (LHD)
6 Series 3 = Sport
4 = Laredo
5 = Limited
6 = Overland
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0 Liter Gasoline
N = 4.7 Liter Gasoline
9 Check Digit 0 through 9 or X
10 Model Year 2=2002
11 Assembly Plant C = Jefferson Assembly
12 thru 17 Vehicle Build Sequence
Fig. 6 VECI Label Location
1 - VECI LABEL (CANADIAN)
2 - VECI LABEL
3 - HOOD
8 INTRODUCTIONWJ

DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used. European Grade 10W-40 oils are also accept-
able.
Oils of the SAE 5W-40 or 8W-80 grade number are
preferred when minimum temperatures consistently
fall below -12ÉC.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID FILL/CHECK
LOCATIONS
INSPECTION - FLUID FILL/CHECK LOCATIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
MAINTENANCE SCHEDULES
DESCRIPTION
9Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.9
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a WJ vehicle (Fig. 7). Support the vehicle in
the raised position with jack stands at the front and
rear ends of the frame rails.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
²An axle tube.
²Aluminum differential.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 7).
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
0 - 6 LUBRICATION & MAINTENANCEWJ
FLUID TYPES (Continued)

LOWER BALL JOINT
REMOVAL
Ball stud service procedures below require removal
of the hub bearing and axle shaft. Removal and
installation of upper and lower ball studs require the
use of Tool Kit 6289.
(1) Position tools as shown to remove and install
ball stud (Fig. 6).
LOWER CONTROL ARM
DESCRIPTION
The lower suspension arms are hydroformed steel
and use voided oval bushings at one end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads from the axle.
REMOVAL
(1) Raise the vehicle and support the front axle.
(2) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 7).
(3) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig.
7).
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Remove support and lower the vehicle.
(5) With the vehicle on the ground tighten the
frame bracket bolt to 156 N´m (115 ft. lbs.). Tighten
the axle bracket nut to 163 N´m (120 ft. lbs.).
(6) Check the alignment if new parts were
installed.
Fig. 6 Lower
1 - SPECIAL TOOL 6289±12
2 - SPECIAL TOOL 6289±4
3 - SPECIAL TOOL 4212F
4 - SPECIAL TOOL 4212F5 - SPECIAL TOOL 6289±1
6 - SPECIAL TOOL 6289±3
WJFRONT 2 - 11

SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
brackets. The standard shocks have conventional
twin tube construction and are low pressure gas
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
REMOVAL
(1) Remove the nut, retainer and grommet from
the shock stud in the engine compartment (Fig. 8).
(2) Raise and support the front axle.
(3) Remove the lower mounting nuts from the axle
bracket (Fig. 9). Remove the shock absorber.
INSTALLATION
(1) Position the lower retainer and grommet on the
shock stud. Insert the shock absorber through the
shock tower hole.
(2) Install the lower shock studs into the axle
bracket.
(3) Install the mounting nuts and tighten to 28
N´m (250 in. lbs.).
(4) Remove support and lower the vehicle.(5) Install the upper grommet, retainer and nut on
the stud in the engine compartment. Hold the shock
stud witha8mmwrench and tighten the nut to 35
N´m (26 ft. lbs.).SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert.
Fig. 7 Lower Suspension Arm
1 - LOWER SUSPENSION ARM
2 - FRAME RAIL BRACKET
3 - AXLE BRACKET
Fig. 8 Upper Shock Mounting
1 - RETAINER
2 - STUD
3 - NUT
4 - GROMMET
Fig. 9 Lower Shock Mounting
1 - SHOCK ABSORBER
2 - MOUNTING NUTS
2 - 12 FRONTWJ
LOWER CONTROL ARM (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)

UPPER CONTROL ARM
DESCRIPTION
The upper suspension arms are hydroformed steel
and use rubber bushings at each end of the arm.
OPERATION
The arms mount to the unibody frame rail bracket
and the axle brackets. The arm and bushings provide
location and react to loads from the axle. The bush-
ings provide isolation from the axle.
REMOVAL
(1) Raise vehicle and support the axle.
(2) Remove the upper suspension arm mounting
nut and bolt (Fig. 17) from the axle bracket.(3) Remove the nut and bolt (Fig. 17) at the frame
rail and remove the upper suspension arm.
INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts.
(3) Remove the supports and lower the vehicle.
(4) With the vehicle on the ground tighten the axle
bracket nut and the frame bracket bolt to 61 N´m (45
ft. lbs.).
(5) Check the alignment if new parts were
installed.
Fig. 17 Upper Suspension Arm
1 - UPPER SUSPENSION ARM
2 - FRAME BOLT
3 - AXLE BOLT
2 - 16 FRONTWJ

SPECIAL TOOLS
REAR SUSPENSION
LOWER CONTROL ARM
DESCRIPTION
The lower suspension arms are hydroformed steel
and use voided oval bushings at each end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads.
REMOVAL
(1) Raise the vehicle and support the rear axle.
(2) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 2).
(3) Remove the nut and bolt (Fig. 2) from the
frame rail and remove the lower suspension arm.
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Remove the supports and lower the vehicle.
(5) With the vehicle on the ground tighten the nut
at the frame to 156 N´m (115 ft. lbs.). Tighten the
nut at the axle bracket to 163 N´m (120 ft. lbs.).
SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
brackets. The standard shocks have conventional
twin tube construction and are low pressure gas
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
CAUTION: Do not allow the axle to hang from the
upper suspension arm ball joint.
(2) Remove the upper nut and bolt from the frame
bracket (Fig. 3).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.
INSTALLATION
(1) Install the shock absorber in the frame bracket
and install the bolt and nut.
(2) Install the shock absorber in the axle bracket
and install the bolt and nut.
(3) Tighten the upper mounting nuts to 108 N´m
(80 ft. lbs.). Tighten the lower mounting nuts to 115
N´m (85 ft. lbs.).
(4) Remove the supports and lower the vehicle.
Remover 8278
Fig. 2 Lower Suspension Arm
1 - LOWER SUSPENSION ARM
2 - AXLE BRACKET
3 - FRAME BRACKET
WJREAR 2 - 19
REAR (Continued)

SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert. The
isolators provide road noise isolation
OPERATION
The coil springs control ride quality and maintain
proper ride height.
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
(2) Remove the wheel and tire assemblies.
(3) Remove the stabilizer bar link from the stabi-
lizer bar (Fig. 4).
(4) Remove the shock absorber lower bolt from the
axle bracket.
(5) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 4).
(6) Remove and inspect the upper and lower
spring isolators (Fig. 4).
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 5).
(3) Pull down on the axle and position the coil
spring in the lower isolator.CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 6).
(4) Raise the axle with the hydraulic jack.
(5) Install the shock absorber to the axle bracket
and tighten to specification.
(6) Install the stabilizer bar link to the stabilizer
bar.
(7) Install the wheel and tire assemblies.
(8) Remove the supports and lower the vehicle.
(9) Tighten the stabilizer bar links to specification.
Fig. 3 Shock Absorber
1 - SHOCKFig. 4 Coil Spring
1 - COIL SPRING
2 - ISOLATOR
3 - STABILIZER LINK
4 - ISOLATOR
Fig. 5 Isolator Locator Nub
1 - LOWER ISOLATOR
2 - LOCATOR NUB
3 - AXLE SPRING PAD
2 - 20 REARWJ
SHOCK (Continued)