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

SPECIAL TOOLS
BASE BRAKESBRAKE FLUID LEVEL SWITCH
REMOVAL
(1) Remove the wire connector from the fluid level
sensor.
(2) From the same side of the master cylinder res-
ervoir release the sensor locking taps with a small
screw driver.
(3) Pull the sensor out of the reservoir from the
connector side of the sensor.
INSTALLATION
(1) Install the sensor with a new o-ring into the
reservoir until the locking tabs are engaged.
(2) Install the wire connector to the fluid level sen-
sor.
RED BRAKE WARN INDICATOR
SWITCH
DESCRIPTION
A red warning lamp is used for the service brake
portion of the hydraulic system. The lamp is located
in the instrument cluster.
OPERATION
The lamp is turned on momentarily when the igni-
tion switch is turn to the on position. This is a self
test to verify the lamp is operational.
The red warning light alerts the driver if the fluid
level is low or the parking brakes are applied. A red
warning lamp with an amber warning lamp may
indicate a electronic brake distribution fault.
DIAGNOSIS AND TESTING - RED BRAKE
WARNING LAMP
The red warning lamp illuminates when the park-
ing brake is applied or when the fluid level in the
master cylinder is low. It will also illuminate at start
up as part of a bulb check.
If the light comes on, first verify that the parking
brakes are fully released. Then check pedal action
and fluid level. If a problem is confirmed, inspect the
brake hydraulic system for leaks.
A red warning lamp with a amber warning lamp
may indicate a electronic brake distribution fault.
Installer Caliper Dust Boot 8280
Handle C-4171
Adapter Pressure Bleeder 6921
WJBRAKES - BASE 5 - 7
BRAKES - BASE (Continued)

ADJUSTABLE PEDAL SWITCH
REMOVAL
(1) Remove the steering column opening cover
(Fig. 2)(Refer to 23 - BODY/INSTRUMENT PANEL/
STEERING COLUMN OPENING COVER - REMOV-
AL).
(2) Disconnect the electrical connector from the
adjustable pedal switch.
(3) Remove the switch from the steering column
opening cover by squeezing the retaining clips
together and pushing the switch outwards (Fig. 3).
INSTALLATION
(1) Install the switch to the steering column open-
ing cover by pushing the switch inwards seating the
retaining clips to the steering column opening cover
(Fig. 3).
(2) Reconnect the electrical connector to the
adjustable pedal switch.
(3) Install the steering column opening cover (Fig.
2)(Refer to 23 - BODY/INSTRUMENT PANEL/
STEERING COLUMN OPENING COVER - INSTAL-
LATION).
BRAKE LINES
DESCRIPTION
Flexible rubber hose is used at both front brakes,
rear brakes and at the rear axle junction block. Dou-
ble walled steel tubing is used. Double inverted style
and ISO style flares are used on the brake lines.
DIAGNOSIS AND TESTING - BRAKE HOSES
AND LINES
Flexible rubber hose is used at both front and rear
brakes and at the rear axle junction block. Inspect
the hoses whenever the brake system is serviced, at
every engine oil change, or whenever the vehicle is in
for service.
Inspect the hoses for surface cracking, scuffing, or
worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed due to cracks
or abrasions.
Also check brake hose installation. Faulty installa-
tion can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, twists, kinks, leaks, or
other damage. Heavily corroded lines will eventually
rust through causing leaks. In any case, corroded or
damaged brake lines should be replaced.
Factory replacement brake lines and hoses are rec-
ommended to ensure quality, correct length and supe-
rior fatigue life. Care should be taken to make sure
that brake line and hose mating surfaces are clean
and free from nicks and burrs. Also remember that
right and left brake hoses are not interchangeable.
Use new copper gaskets at all caliper connections.
Be sure brake line connections are properly made
(not cross threaded) and tightened to recommended
torque.
Fig. 2 STEERING COLUMN OPENING COVER
REMOVAL/INSTALL
1 - INSTRUMENT PANEL TOP PAD
2 - STEERING COLUMN OPENING COVER
3 - SCREW (3)
Fig. 3 ADJUSTABLE PEDAL SWITCH
1 - RETAINING CLIPS
2 - ELECTRICAL CONNECTION
5 - 8 BRAKES - BASEWJ

rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder with
reservoir, caliper seals, HCU and all hydraulic fluid
hoses.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.
No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) Remove reservoir cap and remove fluid with a
cleansuction gun.
(2) Remove the wire connector from the brake fluid
level sensor.
(3) Insert the tool (Fig. 47) provided with the res-
ervoir to release the reservoir retaining tabs.
(4) Pull the reservoir straight up out of the cylin-
der.
(5) Remove and discard grommets from the cylin-
der body.
INSTALLATION
(1) Lubricate new grommets with clean brake
fluid. Install new grommets into the cylinder body.
CAUTION: Do not use tools to install the grommets.
Tools may cut, or tear the grommets. Install the
grommets using finger pressure only.(2) Start reservoir in grommets then press the res-
ervoir straight down to seat the reservoir into the
cylinder grommets.
CAUTION: Do not rock the reservoir during installa-
tion.
(3) Verify retaining tabs are seated.
(4) Install the wire connector to the brake fluid
level sensor.
(5) Fill master cylinder.
MASTER CYLINDER
DESCRIPTION
The master cylinder body is made of aluminum
and contains a primary and secondary piston assem-
bly. The cylinder body including the piston assem-
blies are not serviceable. If diagnosis indicates an
internal problem with the cylinder body, it must be
replaced as an assembly. The master cylinder has a
removable reservoir and fluid level indicator. The res-
ervoir, reservoir grommets, reservoir cap and fluid
level switch are the only replaceable parts on the
master cylinder.
Fig. 47 Release Tool
1 - RESERVOIR
2 - RELEASE TOOL
3 - RETAINING TABS
WJBRAKES - BASE 5 - 23
FLUID (Continued)

STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING PROCEDURE
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise with brass jaws.
(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into the bottom of the
reservoir (Fig. 50).
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return under
spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Remove the wire connector from the brake fluid
level sensor.
(2) Remove brake lines from master cylinder.
(3) Remove nuts that attach master cylinder to
booster studs (Fig. 51).
(4) Remove master cylinder from booster.
INSTALLATION
NOTE: Bleed new master cylinder on bench before
installation, refer to Service Procedures.
(1) Have an assistant depress the brake pedal
while guiding the master cylinder on the booster rod
and mounting studs.
CAUTION: Do not depress brake pedal too hard and
ensure the booster rod is in the master cylinder pis-
ton or booster/master cylinder damage will occur.(2) Install master cylinder mounting nuts and
tighten nuts to 25 N´m (18 lb. lbs.).
NOTE: Use original or factory replacement nuts only.
(3) Install brake lines and tighten to 16 N´m (144
in. lbs.).
(4) Install fluid level sensor connector.
(5) Fill and bleed brake system.
PEDAL
DESCRIPTION
DESCRIPTION - STANDARD PEDAL
A suspended-type brake pedal is used, the pedal
pivots on a shaft mounted in the pedal support
bracket. The bracket is attached to the dash panel.
The brake pedal assembly and pedal pad are the
only serviceable component.
DESCRIPTION - ADJUSTABLE PEDALS
The Adjustable Pedals System (APS) is designed to
enable the fore and aft repositioning of the brake and
accelerator pedals. This results in improved ergonom-
ics in relation to the steering wheel for taller and
shorter drivers. Being able to adjust the pedal posi-
Fig. 50 Master Cylinder Bleeding
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 51 Master Cylinder Mounting
1 - MOUNTING NUT
2 - SENSOR CONNECTOR
3 - MOUNTING NUT
4 - BRAKE LINES
WJBRAKES - BASE 5 - 25
MASTER CYLINDER (Continued)

(2) Remove nut from pedal shaft.
(3) Slide pedal shaft out and remove brake pedal.
(4) Remove pedal bushings (Fig. 54) if they are to
be replaced.
REMOVAL - ADJUSTABLE PEDALS
NOTE: If possible put the pedals in the full forward
position.
(1) Disconnect the negative battery cable.
(2) Remove the cluster bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL - REMOV-
AL).
(3) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(4) Disconnect the module electrical connector.
(5) Remove the brake light switch.
(6) Disconnect the booster rod clip (Fig. 53).
(7) Disconnect the accelerator cable from the
pedal.
(8) Lock the steering wheel into place.
(9) Remove the lower steering shaft pinch bolt
(Fig. 56).
(10) Separate the lower shaft coupler and push for-
ward (Fig. 56).
(11) Remove the two pedal bracket upper nuts
(Fig. 55).
(12) Remove the brake booster nuts (Fig. 56).
(13) Remove the accelerator pedal nuts (Fig. 57).(14) Remove the ICU mounting bracket nuts and
bolts and move the ICU and booster forward this will
allow enough clearance to remove the adjustable
pedal bracket from over the booster push rod.
(15) Remove the pedal from the vehicle (Fig. 56).
(16) Transfer the module if needed.
Fig. 54 Pedal Bushings
1 - BUSHING
2 - BUSHING
3 - SHAFT NUT
4 - PEDAL SHAFT
Fig. 55 UPPER MOUNTING NUTS
1 - UPPER MOUNTING STUDS
2 - ACCELERATOR MOUNTING STUDS
3 - UPPER MOUNTING NUT
4 - MOTOR
5 - ADJUSTABLE PEDAL BRACKET
Fig. 56 ADJUSTABLE PEDAL BRACKET
1 - BRAKE LIGHT SWITCH
2 - STEERING COLUMN
3 - ACCELERATOR PEDAL
4 - ADJUSTABLE PEDALS MOUNTING BRACKET
5 - BRAKE PEDAL
6 - MOTOR MOUNTING BRACKET
7 - BRAKE BOOSTER MOUNTING NUTS
(4)
WJBRAKES - BASE 5 - 27
PEDAL (Continued)

INSTALLATION
INSTALLATION - NON-ADJUSTABLE PEDAL
(1) Lubricate bushings, pedal shaft and pedal pin
with Mopar multi-mileage grease.
(2) Install bushings into pedal.
(3) Position pedal in bracket and install pedal
shaft in support and through pedal.
(4) Install new nut on pedal shaft and tighten to
27 N´m (20 ft. lbs.).
NOTE: Pedal shaft nut should not be reused.
(5) Install booster push rod on pedal pin and
install retainer clip on pedal pin.
(6) Check and adjust stop lamp switch if necessary.
INSTALLATION - ADJUSTABLE PEDALS
(1) Install the pedal to the vehicle (Fig. 56).
(2) Reposition the ICU and booster, Install the
ICU mounting bracket nuts and bolts.
28 N
(3) Install the brake booster nuts. Tighten to 28
N´m ( 21 ft. lbs.). (Fig. 56).
(4) Install the pedal bracket upper nuts. Tighten
to 12 N´m ( 9 ft. lbs.). (Fig. 56).
(5) Install the accelerator pedal nuts. Tighten to
28 N´m ( 21 ft. lbs.). (Fig. 57).
(6) Install the lower steering shaft coupler over the
shaft (Fig. 56).
(7) Install the lower steering shaft pinch bolt (Fig.
56).
(8) Unlock the steering wheel.
(9) Reconnect the accelerator cable to the pedal
(Fig. 56).(10) Reconnect the booster rod clip (Fig. 56).
(11) Install the brake light switch.
(12) Reconnect the module electrical connector.
(13) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(14) Install the cluster bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(15) Reconnect the negative battery cable.
PEDAL MOTOR
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the cluster bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL - REMOV-
AL).
(3) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(4) Remove the two mounting screws (Fig. 58).
(5) Disconnect the electrical connector (Fig. 58).
(6) Remove the adjustable pedal motor (Fig. 58).
INSTALLATION
(1) Install the adjustable pedal motor (Fig. 58).
(2) Reconnect the electrical connector (Fig. 58).
(3) Install the two mounting screws (Fig. 58).
(4) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
Fig. 57 ACCELERATOR MOUNTING BRACKET
1 - ACCELERATOR MOUNTING NUTS
2 - ADJUSTABLE PEDALS BRACKET
3 - ACCELERATOR PEDAL
Fig. 58 ADJUSTABLE PEDALS MOTOR
1 - ELECTRICAL CONNECTOR
2 - PEDALS MOTOR
3 - MOUNTING SCREWS HOLES
5 - 28 BRAKES - BASEWJ
PEDAL (Continued)

(8) Remove the park brake lever mounting nuts
and console bracket (Fig. 80).
(9) Lift the lever assembly off the mounting studs
and pull the front cable out of the lever bracket.
INSTALLATION
(1) Install the lever assembly on the mounting
studs while feeding the front cable into the lever
bracket.
(2) Install the console bracket (Fig. 80) and mount-
ing nuts.
(3) Engage the front cable end to the lever.
(4) Connect parking brake switch wire connector.
(5) Pull on the lever to release the lock out spring.
(6) Install center console,(Refer to 23 - BODY/IN-
TERIOR/FLOOR CONSOLE - INSTALLATION).
(7) Fold down the rear carpet cover and rear seat.
SHOES
REMOVAL
(1) Lock out park brake lever (Fig. 81).
(2) Raise vehicle.
(3) Remove rear wheel and tire assembly.
(4) Remove caliper and anchor as an assembly.
(5) Remove rubber access plug from back of rear
disc brake splash shield.
(6) If necessary retract parking brake shoes with
brake adjuster tool (Fig. 82). Position tool at top of
star wheel and rotate wheel.
(7) Remove rotor from axle hub flange.
(8) Remove the lower shoe to shoe spring/adjuster
spring with needle nose pliers (Fig. 83).
(9) Remove the upper shoe to shoe spring/return
spring with brake pliers (Fig. 84).(10) Remove shoe hold-down clips and pins (Fig.
85). Clip is held in place by pin which fits in clip
notch. To remove clip, first push clip ends together
and slide clip until head of pin clears narrow part of
notch. Then remove clip and pin.
(11) Remove shoes and adjuster.
INSTALLATION
(1) Install shoes on splash shield with hold down
clips and pins. Be sure shoes are properly engaged in
the park brake actuator.
(2) Lubricate and install adjuster screw assembly.
Be sure notched ends of screw assembly are properly
seated on shoes and that star wheel is aligned with
access hole in shield.
Fig. 80 Parking Brake Lever Mounting
1 - MOUNTING NUT
2 - PARK BRAKE LEVER
Fig. 81 Lock Out Spring
1 - LOCK OUT SPRING
Fig. 82 Retracting Parking Brake Shoes
1 - ACCESS HOLE
2 - BRAKE ADJUSTING TOOL
3 - SPLASH SHIELD
WJBRAKES - BASE 5 - 39
LEVER (Continued)

DIAGNOSIS AND TESTING - ANTILOCK
BRAKES
The ABS brake system performs several self-tests
every time the ignition switch is turned on and the
vehicle is driven. The CAB monitors the systems
input and output circuits to verify the system is oper-
ating correctly. If the on board diagnostic system
senses that a circuit is malfunctioning the system
will set a trouble code in its memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Electrical section. For test proce-
dures refer to the Chassis Diagnostic Manual.
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM
ABS system bleeding requires conventional bleed-
ing methods plus use of the DRB scan tool. The pro-cedure involves performing a base brake bleeding,
followed by use of the scan tool to cycle and bleed the
HCU pump and solenoids. A second base brake bleed-
ing procedure is then required to remove any air
remaining in the system.
(1) Perform base brake bleeding. (Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(2) Connect scan tool to the Data Link Connector.
(3) Select ANTILOCK BRAKES, followed by MIS-
CELLANEOUS, then ABS BRAKES. Follow the
instructions displayed. When scan tool displays TEST
COMPLETE, disconnect scan tool and proceed.
(4) Perform base brake bleeding a second time.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
OR (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(5) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
G-Sensor Bolt 5.6 Ð 50
Hydraulic Control Unit/Controller
Antilock Brakes
Mounting Bolts12 9 125
Hydraulic Control Unit/Controller
Antilock Brakes
Brake Lines16 Ð 144
Hydraulic Control Unit/Controller
Antilock Brakes
CAB Screws1.8 Ð 16
Wheel Speed Sensors
Front Sensor Bolt12-14 106-124 Ð
Wheel Speed Sensors
Rear Sensor Bolt12-14 106-124 Ð
5 - 42 BRAKES - ABSWJ
BRAKES - ABS (Continued)

G-SWITCH
DESCRIPTION
The G-switch (Fig. 4) is located under the rear
seat. The switch has directional arrow and must be
mounted with the arrow pointing towards the front
of the vehicle.
OPERATION
The switch is monitored by the CAB at all times.
The switch contains three mercury switches which
monitor vehicle deceleration rates (G-force). Sudden
changes in deceleration rates trigger the switch,
sending a signal to the CAB.
REMOVAL
(1) Fold the rear seat bottom assembly up for
access to the switch.
(2) Lift up the carpeting and disconnect the switch
harness (Fig. 5).
(3) Remove the switch mounting bolts and remove
the switch.
INSTALLATION
CAUTION: The mercury switch (inside the
G-Switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig. 6).
(1) Note the position of the locating arrow on the
switch. Position the switch so the arrow faces for-
ward.
(2) Install the switch and tighten the mounting
bolts to 5.6 N´m (50 in. lbs.).
Fig. 2 Left Sensor Connector
1 - LEFT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST PIPE
3 - LEFT FRONT FRAME RAIL
4 - FRONT DRIVESHAFT
Fig. 3 Right Sensor Connector
1 - RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 - ENGINE EXHAUST Y-PIPE
3 - RIGHT FRONT FRAME RAIL
4 - RIGHT LOWER SUSPENSION ARM
Fig. 4 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
5 - 44 BRAKES - ABSWJ
FRONT WHEEL SPEED SENSOR (Continued)

(3) Connect the harness to the switch. Be sure the
harness connector is firmly seated.
(4) Place the carpet in position and fold the rear
seat back down.
REAR WHEEL SPEED SENSOR
DESCRIPTION
A wheel speed sensor is used at each wheel. The
front sensors are mounted to the steering knuckles.The rear sensors are mounted at the outboard end of
the axle. Tone wheels are mounted to the outboard
ends of the front and rear axle shafts. The gear type
tone wheel serves as the trigger mechanism for each
sensor.
OPERATION
The sensors convert wheel speed into a small digi-
tal signal. The CAB sends 12 volts to the sensors.
The sensor has an internal magneto resistance
bridge that alters the voltage and amperage of the
signal circuit. This voltage and amperage is changed
by magnetic induction when the toothed tone wheel
passes the wheel speed sensor. This digital signal is
sent to the CAB. The CAB measures the voltage and
amperage of the digital signal for each wheel.
REMOVAL
(1) Raise and fold the rear seat forward. Then
move the carpeting aside for access to the rear sensor
connectors.
(2) Disconnect the rear sensor wire at the harness
connectors (Fig. 7).
(3) Push the sensor wires and grommets through
the floorpan holes.
(4) Raise and support the vehicle.
(5) Disengage the sensor wire from the axle and
the chassis brackets and from the brake line retain-
ers.
(6) Remove the sensor mounting bolt from the rear
brake backing plate. (Fig. 8).
(7) Remove the sensor from the backing plate.
Fig. 5 G-Switch Mounting
1 - MOUNTING BOLTS
2 - CONNECTOR
3 - G-SWITCH
Fig. 6 G-Switch
1 - SWITCH PART NUMBER
2 - ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
Fig. 7 Rear Sensor Connector
1 - RIGHT REAR WHEEL SPEED SENSOR CONNECTOR
2 - LEFT REAR WHEEL SPEED SENSOR CONNECTOR
3 - G-SWITCH SENSOR
4 - PARKING BRAKE CABLES
WJBRAKES - ABS 5 - 45
G-SWITCH (Continued)