torque JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

SEAT TRACK ADJUSTER
REMOVAL
(1) Remove seat (Refer to 23 - BODY/SEATS/
FRONT SEAT - REMOVAL).
(2) Remove side shield (Refer to 23 - BODY/
SEATS/FRONT SEAT SIDE SHIELD - REMOVAL).
(3) Remove nuts attaching seat track adjuster to
seat cushion frame (Fig. 7) and (Fig. 8). Roll cushion
trim cover up to access the two front nuts.
(4) Disengage clips attaching wire harness to
adjuster.
(5) Disengage seat memory module connector, if
equipped.
(6) Separate seat track from seat cushion frame.
INSTALLATION
(1) Transfer seat memory module, if equipped.
(2) Position seat track on seat cushion frame.
(3) Route harness through frame and engage clips
attaching wire harness to adjuster.
(4) Engage seat memory module connector, if
equipped.
(5) Install nuts attaching seat track adjuster to
seat cushion frame. Tighten nuts to 28 N´m (20 ft.
lbs.) torque.
(6) Install the side shield (Refer to 23 - BODY/
SEATS/FRONT SEAT SIDE SHIELD - INSTALLA-
TION).
(7) Install seat (Refer to 23 - BODY/SEATS/
FRONT SEAT - INSTALLATION).
Fig. 7 Seat Track AdjusterÐPower
1 - BACK PANEL
2 - LUMBAR ASSEMBLY
3 - SEAT CUSHION FRAME
4 - POWER SEAT TRACK ADJUSTER
5 - POWER RECLINER
6 - SEAT CUSHION PAD
7 - SEAT BACK FRAME
Fig. 8 Seat Track Adjuster Ð Manual
1 - MANUAL RECLINER
2 - SEAT CUSHION PAD
3 - SEAT BACK FRAME
4 - SEAT CUSHION FRAME
5 - MANUAL SEAT TRACK ADJUSTER
WJSEATS 23 - 87

REAR HEADREST SLEEVE
REMOVAL
(1) Remove seat back (Refer to 23 - BODY/SEATS/
REAR SEAT BACK - REMOVAL).
(2) Remove head rest (Refer to 23 - BODY/SEATS/
REAR HEADREST - REMOVAL).
(3) Remove head rest caps.
(4) Remove seat back cover (Refer to 23 - BODY/
SEATS/REAR SEAT BACK COVER - REMOVAL).
(5) Rotate head rest sleeve 1/4 turn counter-clock-
wise to release retaining tab.
(6) Pull sleeve from seat back frame.
INSTALLATION
(1) Position sleeve in seat back frame.
(2) Rotate head rest sleeve 1/4 turn clockwise to
engage retaining tab.
(3) Install seat back cover (Refer to 23 - BODY/
SEATS/REAR SEAT BACK COVER - INSTALLA-
TION).
(4) Install head rest caps.
NOTE: The head rest cap with the taller button is
always on the inboard side of the seat back.
(5) Install the head rest (Refer to 23 - BODY/
SEATS/REAR HEADREST - INSTALLATION).
NOTE: The folding head rest release knob is always
on the outboard side.
(6) Install the seat back (Refer to 23 - BODY/
SEATS/REAR SEAT BACK - INSTALLATION).
REAR SEAT BACK
REMOVAL
(1) Move rear seat cushions to forward cargo posi-
tion.
(2) Remove bolts attaching seatback side support
bracket to floor pan (right side) (Fig. 11).
(3) Tilt seatback forward, and slide it outboard to
detach it from pin on center pivot bracket.
(4) Remove right side (60%) seatback from vehicle.
(5) Remove bolts attaching seatback side support
bracket and center pivot bracket to floor pan (left
side).
(6) Remove left side (40%) seatback from vehicle.
INSTALLATION
(1) Position left side (40%) seatback in vehicle.
(2) Position left side support bracket and center
pivot bracket with bolt holes aligned and install
bolts. Tighten bolts to 28 N´m (20 ft. lbs.) torque.
(3) Position right side (60%) seatback in vehicle.
(4) Install seatback onto center pivot bracket pin.
Ensure seat back is properly engaged on the center
pivot pin.
(5) Position right side support bracket with bolt
holes aligned and install bolts. Tighten bolts to 28
N´m (20 ft. lbs.) torque.
(6) Return seat cushions to seating position.
Fig. 11 Rear Seat Back
1 - SEAT BACK
2 - FLOOR PAN
3 - CENTER PIVOT BRACKET
4 - SIDE SUPPORT BRACKET
WJSEATS 23 - 89

REAR SEAT BACK COVER
REMOVAL
(1) Remove seat back (Refer to 23 - BODY/SEATS/
REAR SEAT BACK - REMOVAL).
(2) Remove head restraint (Refer to 23 - BODY/
SEATS/REAR HEADREST - REMOVAL).
(3) Remove head restraint caps.
(4) Disengage J-straps on outboard side of seat
back.
(5) Disengage J-straps at base of seat back.
(6) Remove screws attaching latch release handle
to seat back frame.
(7) Roll seat back cover upward.
(8) Disengage hook and loop fasteners attaching
seat back cover to seat back pad (Fig. 12).
(9) Roll seat back cover upward and route latch
release handle through seat back cover.
(10) Separate seat back cover from seat back.
(11) Separate seat back pad from seat back frame.
INSTALLATION
(1) Position seat back cover and pad on seat back
frame.
(2) Route latch release handle through seat back
cover.(3) Roll seat back cover partially downward align-
ing holes in seat back cover for head restraint and
latch release handle.
(4) Roll seat back cover downward align and
engage hook and loop fasteners to seat back pad.
(5) Engage J-straps at base of seat back.
(6) Engage J-straps on outboard side of seat back.
(7) Install screws attaching latch release handle to
seat back frame.
(8) Install head restraint (Refer to 23 - BODY/
SEATS/REAR HEADREST - INSTALLATION).
(9) Install seat back (Refer to 23 - BODY/SEATS/
REAR SEAT BACK - INSTALLATION).
REAR SEAT CUSHION
REMOVAL
(1) Disengage seat cushion at rear by pulling
upward on release strap.
(2) Remove bolts attaching seat cushion to floor
pan (Fig. 13).
(3) Remove seat cushion from vehicle.
INSTALLATION
(1) Position seat cushion in vehicle.
(2) Install bolts attaching seat cushion to floor
pan. Tighten bolts to 11 N´m (8 ft. lbs.) torque.
(3) Lock seat cushion down by pressing firmly on
center of cushion until latch engages.
Fig. 12 Rear Seat Back Cover
1 - SEAT BACK COVER
2 - SEAT BACK PAD
3 - HOOK AND LOOP FASTENERFig. 13 Rear Seat Cushion
1 - SEAT CUSHION
2 - FLOOR PAN
23 - 90 SEATSWJ

REAR SEAT CUSHION COVER
REMOVAL
(1) Remove rear seat cushion (Refer to 23 - BODY/
SEATS/REAR SEAT CUSHION - REMOVAL).
(2) From the underside of the seat, disengage
J-straps attaching cover to seat cushion base panel.
(3) Remove push-in fasteners attaching cushion
cover to seat cushion base panel (Fig. 14).
(4) Roll back cover.
(5) Disengage hog rings attaching cushion cover to
seat cushion foam pad.
(6) Separate cushion cover from seat cushion foam
pad.
INSTALLATION
(1) Position cushion cover on seat cushion foam
pad.
(2) Engage hog rings attaching cushion cover to
seat cushion foam pad.
(3) Align cushion cover and engage J-straps
attaching cushion cover to seat cushion base panel.
(4) Install push-in fasteners attaching cushion
cover to seat cushion base panel.
(5) Install rear seat cushion (Refer to 23 - BODY/
SEATS/REAR SEAT CUSHION - INSTALLATION).
REAR SEAT CUSHION
RELEASE LATCH
REMOVAL
(1) Unlatch seat and pivot seat upward.
(2) Disengage J-strap at seat cushion base panel.
(3) Roll back cushion cover.(4) Remove screws attaching latch to base panel.
(5) Separate latch from base panel.
INSTALLATION
(1) Position latch on base panel.
(2) Install screws attaching latch to base panel.
Tighten screws to 8 N´m (75 in. lbs.) torque.
(3) Route the cushion release strap from the loop
on the latch through the slot in the trim cover.
(4) Engage J-strap at seat cushion base panel.
(5) latch seat.
FOLDING REAR SEAT BACK
LATCH HANDLE
REMOVAL
(1) Pull handle to release latch.
(2) Remove screws attaching release handle to seat
back frame.
(3) Using a small flat blade, disengage retainers
securing latch release cable housing to latch release
handle.
(4) Rotate cable end until barrel end aligns with
key hole slot in latch release handle.
(5) Disengage cable barrel end from release han-
dle.
(6) Separate latch release handle from seat back
(Fig. 15).
Fig. 14 Push-in Fasteners
1 - CUSHION COVER
2 - SEAT CUSHION BASE PANEL
3 - PUSH-IN FASTENER
Fig. 15 Rear Seat Release Handle
1 - REAR SEAT FOLDING RELEASE HANDLE
WJSEATS 23 - 91

INSTALLATION
(1) Route cable end into latch release handle.
(2) Rotate cable end until barrel end aligns with
key hole slot in latch release handle and insert into
handle.
(3) Engage retainers securing latch release cable
housing to latch release handle.
(4) Position latch release handle in seat back.
Ensure seat back cover is properly aligned.
(5) Install screws attaching release handle to seat
back frame.
FOLDING REAR SEAT BACK
LATCH/HINGE
REMOVAL
(1) Remove seat back (Refer to 23 - BODY/SEATS/
REAR SEAT BACK - REMOVAL).
(2) Disengage J-straps on outboard side of seat
back.
(3) Disengage release cable from latch.
(4) Remove bolts attaching latch/hinge to seat back
frame.
(5) Separate latch/hinge from seat back frame.
INSTALLATION
(1) Position latch/hinge on seat back frame.
(2) Install bolts attaching latch/hinge to seat back
frame. Tighten bolts to 28 N´m (20 ft. lbs.) torque.
(3) Engage latch release cable.
(4) Engage J-straps on outboard side of seat back.
(5) Install seat back (Refer to 23 - BODY/SEATS/
REAR SEAT BACK - INSTALLATION).
23 - 92 SEATSWJ
FOLDING REAR SEAT BACK LATCH HANDLE (Continued)

(6) Push sunshade down until the sunshade clears
the glass then move sunshade rearward behind the
glass panel.
HOUSING ASSEMBLY
REMOVAL
(1) Move glass panel to the fully closed position.
(2) Disconnect battery negative cable.
(3) Recline both front seats.
(4) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(5) Disconnect the drain tubes from sunroof hous-
ing (Fig. 7).
(6) Loosen fasteners attaching sunroof housing
assembly.
(7) With the aid of a helper, remove fasteners
attaching sunroof housing assembly to roof panel.
INSTALLATION
(1) Raise the sunroof housing assembly and guide
into position and start fasteners (Fig. 7).
(2) Tighten the fasteners, front to rear, attaching
the sunroof module to roof panel. Tighten the fasten-
ers, front to rear, to 11 N´m (97 in. lbs.) torque.
(3) Connect the drain tubes to the sunroof housing.
(4) Set headliner into position.
(5) Connect express module, drive motor, and con-
trol switch wire connectors.
(6) Test sunroof operation, adjust as necessary.
(7) Finish installing the headliner. (Refer to 23 -
BODY/INTERIOR/HEADLINER - INSTALLATION)
(8) Connect battery negative cable.
Fig. 7 SUNROOF ASSEMBLY
1 - ROOF
2 - DRAIN HOSE
3 - CLAMP
4 - SUNROOF ASSEMBLY
5 - CLAMP
6 - DRAIN HOSE
23 - 104 SUNROOFWJ
SUNSHADE (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS.......................1
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT........................1
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT........................2DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................2
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE.......................6
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................6
SPECIFICATIONS
A/C APPLICATION TABLE................7
TORQUE SPECIFICATIONS..............8
CONTROLS.............................9
DISTRIBUTION..........................36
PLUMBING.............................51
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the heating-
air conditioning system, the engine cooling system
must be properly maintained. The use of a bug
screen is not recommended. Any obstructions in front
of the radiator or condenser will reduce the perfor-
mance of the air conditioning and engine cooling sys-
tems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Cooling for more infor-
mation before opening, or attempting any service to
the engine cooling system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manual temperature control type heating-air
conditioning system is standard factory-installed
equipment on this model. An electronically controlled
Automatic Zone Control (AZC) type heating-air con-
ditioning system is an available factory-installed
option.
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel.DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service port
coupler sizes are used on the R-134a system to
ensure that the refrigerant system is not accidentally
contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
Fig. 1 Blend-Air HVAC System - (typical)
1 - Blend Door
2 - Expansion Valve
3 - Evaporator Core
4 - Blower Assembly
5 - Recirculation Door
6 - Evaporator Probe
7 - Heater Core
8 - Heat/Defrost Door
9 - Panel/Defrost Door
WJHEATING & AIR CONDITIONING 24 - 1

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
A/C COMPRESSOR
SHAFT BOLT13 9.6 115
A/C COMPRESOR LINE
MANIFOLD FASTENERS
4.0L/4.7L25.4 18.75 225
A/C COMPRESOR LINE
MANIFOLD FASTENERS
2.7L DIESEL22 16.2 195
A/C COMPRESSOR TO
ENGINE BLOCK BOLTS -
4.0L/4.7L45-65 33-48 398-575
A/C COMPRESSOR TO
ENGINE BLOCK BOLTS -
2.7L DIESEL30 22 266
A/C COMPRESSOR REAR
BRACE BOLTS - 4.0L40-55 30-41 354-487
A/C COMPRESSOR REAR
BRACE BOLTS - 4.7L35-45 26-33 310-398
A/C CONDENSER TO
REFRIG. LINE
FASTENERS28 21 248
A/C EVAPORATOR LINE to
TXV FASTENERS28 21 247
ACCUMULATOR
RETAINING BAND
(4.0L/4.7L)12 9.0 106
ACCUMULATOR
RETAINING BAND (3.1L
DIESEL)5 3.7 44
BLOWER MOTOR
SCREWS2.2 1.7 20
DOOR ACTUATOR
SCREWS2.2 1.7 20
HVAC HOUSING SCREWS 2.2 1.7 20
HVAC HOUSING TO DASH
PANEL NUTS (ENGINE
COMP. SIDE)75 62
HVAC HOUSING TO DASH
PANEL NUTS
(PASSENGER COMP.
SIDE)4.5 3.3 40
EXPANSION VALVE TO
HVAC FASTENERS20 15 177
SUCTION LINE TO
ACCUMULATOR FITTING28 20.7 248
24 - 8 HEATING & AIR CONDITIONINGWJ
HEATING & AIR CONDITIONING (Continued)

STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C Heater control in the
Recirculation Mode, the A/C button in the on posi-
tion, the blower motor switch in the highest speed
position, and the engine speed at 1500 to 2000 rpm.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher compressor
clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt. Refer to
Cooling for the procedures.
(3) Remove the bolt that secures the compressor
clutch to the compressor shaft (Fig. 5). A band-type
oil filter wrench may be used to secure the clutch
during bolt removal.
(4) Tap the clutch plate with a plastic mallet to
release it from the splines on the compressor shaft.
Remove the clutch plate and shim(s) from the com-
pressor shaft (Fig. 6).
CAUTION: Do not pry between the clutch plate
assembly and the pulley to remove it from the com-
pressor shaft. Prying may damage the clutch plate
assembly.(5) Remove the external snap ring that secures the
compressor clutch pulley to the nose of the compres-
sor front housing with snap ring pliers (Special Tool
C-4574) and slide the pulley assembly off of the com-
pressor (Fig. 7).
(6) Remove the screw and retainer from the clutch
coil lead wire harness on the compressor front hous-
ing.
Fig. 5 COMPRESSOR SHAFT BOLT
1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
Fig. 6 CLUTCH PLATE AND SHIM(S)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
Fig. 7 PULLEY SNAP RING
1 - SNAP RING
24 - 14 CONTROLSWJ
A/C COMPRESSOR CLUTCH (Continued)

CAUTION
CAUTION
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a
system. Damage to the system will result.
Do not overcharge the refrigerant system. This will
cause excessive compressor head pressure and
can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
The refrigerant system must always be evacuated
before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
Before disconnecting a component, clean the out-
side of the fittings thoroughly to prevent contami-
nation from entering the refrigerant system.
Immediately after disconnecting a component from
the refrigerant system, seal the open fittings with a
cap or plug.
Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
Do not remove the sealing caps from a replacement
component until it is to be installed.
When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
vent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.Keep service tools and the work area clean. Con-
tamination of the refrigerant system through care-
less work habits must be avoided.REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing
will reduce the capacity of the entire system. High
pressures are produced in the system when it is oper-
ating. Extreme care must be exercised to make sure
that all refrigerant system connections are pressure
tight.
A good rule for the flexible hose refrigerant lines is
to keep the radius of all bends at least ten times the
diameter of the hose. Sharp bends will reduce the
flow of refrigerant. The flexible hose lines should be
routed so they are at least 80 millimeters (3 inches)
from the exhaust manifold. It is a good practice to
inspect all flexible refrigerant system hose lines at
least once a year to make sure they are in good con-
dition and properly routed.
There are two types of refrigerant fittings:
²All fittings with O-rings need to be coated with
refrigerant oil before installation. Use only O-rings
that are the correct size and approved for use with
R-134a refrigerant. Failure to do so may result in a
leak.
²Unified plumbing connections with gaskets can-
not be serviced with O-rings. The gaskets are not
reusable and new gaskets do not require lubrication
before installing.
Using the proper tools when making a refrigerant
plumbing connection is very important. Improper
tools or improper use of the tools can damage the
refrigerant fittings. Always use two wrenches when
loosening or tightening tube fittings. Use one wrench
to hold one side of the connection stationary, while
loosening or tightening the other side of the connec-
tion with a second wrench.
The refrigerant must be recovered completely from
the system before opening any fitting or connection.
Open the fittings with caution, even after the refrig-
erant has been recovered. If any pressure is noticed
as a fitting is loosened, tighten the fitting and
recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere.
Use an R-134a refrigerant recovery/recycling device
that meets SAE Standard J2210.
The refrigerant system will remain chemically sta-
ble as long as pure, moisture-free R-134a refrigerant
and refrigerant oil is used. Dirt, moisture, or air can
upset this chemical stability. Operational troubles or
serious damage can occur if foreign material is
present in the refrigerant system.
When it is necessary to open the refrigerant sys-
tem, have everything needed to service the system
WJPLUMBING 24 - 53
PLUMBING (Continued)