Table of contents JEEP GRAND CHEROKEE 2003 WJ / 2.G Service Manual

WIPERS/WASHERS
TABLE OF CONTENTS
page page
FRONT WIPERS/WASHERS.................. 1REAR WIPERS/WASHERS.................. 33
FRONT WIPERS/WASHERS
TABLE OF CONTENTS
page page
FRONT WIPERS/WASHERS
DESCRIPTION..........................2
OPERATION............................4
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM.....................6
CLEANING - FRONT WIPER & WASHER
SYSTEM.............................8
INSPECTION - FRONT WIPER & WASHER
SYSTEM.............................8
FRONT CHECK VALVE
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................9
INSTALLATION.........................10
FRONT WASHER HOSES/TUBES
DESCRIPTION.........................10
OPERATION...........................11
FRONT WASHER NOZZLE
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11
FRONT WASHER PUMP/MOTOR
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................13
FRONT WIPER ARM
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................14
FRONT WIPER BLADE
DESCRIPTION.........................14
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................15
FRONT WIPER MODULE
DESCRIPTION.........................16OPERATION...........................16
REMOVAL.............................17
INSTALLATION.........................17
RAIN SENSOR MODULE
DESCRIPTION.........................18
OPERATION...........................18
REMOVAL.............................19
INSTALLATION.........................19
RIGHT MULTI-FUNCTION SWITCH
DESCRIPTION.........................20
OPERATION...........................21
DIAGNOSIS AND TESTING - RIGHT MULTI-
FUNCTION SWITCH...................22
REMOVAL.............................24
INSTALLATION.........................24
WASHER FLUID LEVEL SWITCH
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................26
INSTALLATION.........................26
WASHER RESERVOIR
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................28
WIPER HIGH/LOW RELAY
DESCRIPTION.........................29
OPERATION...........................29
DIAGNOSIS AND TESTING - WIPER HIGH/
LOW RELAY.........................30
REMOVAL.............................30
INSTALLATION.........................30
WIPER ON/OFF RELAY
DESCRIPTION.........................31
OPERATION...........................31
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY..............................32
REMOVAL.............................32
INSTALLATION.........................32
WJWIPERS/WASHERS 8R - 1

REAR WIPERS/WASHERS
TABLE OF CONTENTS
page page
REAR WIPERS/WASHERS
DESCRIPTION.........................33
OPERATION...........................34
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM....................35
CLEANING - REAR WIPER & WASHER
SYSTEM............................37
INSPECTION - REAR WIPER & WASHER
SYSTEM............................37
REAR WASHER HOSES/TUBES
DESCRIPTION.........................38
OPERATION...........................39
REAR WASHER NOZZLE
DESCRIPTION.........................39
OPERATION...........................39
REMOVAL.............................39
INSTALLATION.........................40
REAR WASHER PUMP/MOTOR
DESCRIPTION.........................40
OPERATION...........................40REMOVAL.............................41
INSTALLATION.........................41
REAR WIPER ARM
DESCRIPTION.........................41
OPERATION...........................42
REMOVAL.............................42
INSTALLATION.........................42
REAR WIPER BLADE
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................44
INSTALLATION.........................44
REAR WIPER MODULE
DESCRIPTION.........................44
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................45
WIPER ARM PARK RAMP
REMOVAL.............................46
INSTALLATION.........................46
REAR WIPERS/WASHERS
DESCRIPTION
An electrically operated fixed interval intermittent
rear wiper and washer system is standard factory-in-
stalled equipment on this model. The rear wiper and
washer system includes the following major compo-
nents, which are described in further detail else-
where in this service information:
²Rear Washer Nozzle- The rear washer nozzle
is secured by a snap fit onto the top of the liftgate
outer panel above the liftgate glass. The rear washer
nozzle includes an integral check valve. The rear
washer system plumbing is concealed within and
routed through the interior of the vehicle.
²Rear Washer Pump/Motor- The rear washer
pump/motor unit is located in a dedicated hole on the
lower outboard side of the washer reservoir, ahead of
the left front wheel housing. The rear washer pump
mounting hole is located higher on the reservoir than
the front washer pump mounting hole.
²Rear Wiper Arm- The single rear wiper arm is
secured by a nut directly to the rear wiper module
output shaft, which extends through the liftgate
outer panel near the base of the liftgate glass.²Rear Wiper Arm Park Ramp- The molded
rubber rear wiper arm park ramp is secured with a
screw to the liftgate outer panel, just below the right
side of the liftgate glass. When the rear wiper system
is not in operation, the rear wiper arm is parked on
this ramp so that it will not interfere with or be
damaged by liftgate flip-up glass operation.
²Rear Wiper Blade- The single rear wiper
blade is secured to the rear wiper arm, and is moved
off of the liftgate glass when the rear wiper system is
not in operation.
²Rear Wiper Module- The rear wiper module
output shaft is the only visible component of the rear
wiper module. The remainder of the module is con-
cealed within the liftgate beneath the liftgate glass
opening. The rear wiper module includes the module
bracket, the rear wiper motor, and the rear wiper
module electronic control circuitry.
²Right Multi-Function Switch- The right
(wiper) multi-function switch is secured to the right
side of the multi-function switch mounting housing
near the top of the steering column. Only the control
stalk for the right multi-function switch is visible,
the remainder of the switch is concealed beneath the
steering column shrouds. The right multi-function
switch contains all of the switches and control cir-
cuitry for both the front and rear wiper and washer
systems.
WJREAR WIPERS/WASHERS 8R - 33

WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
JUNCTION BLOCK.................... 8W-12-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
POWER SUNROOF................... 8W-64-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUT................ 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION............... 8W-97-1 WJWIRING 8W - 1

8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS...........................1
DESCRIPTION - CIRCUIT INFORMATION....5
DESCRIPTION - CIRCUIT FUNCTIONS......6
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION....................6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION..............7
WARNING
WARNINGS - GENERAL.................7
DIAGNOSIS AND TESTING - WIRING
HARNESS............................7
STANDARD PROCEDURE
STANDARD PROCEDURE -
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES...................8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL...................9
STANDARD PROCEDURE - TESTING FOR
CONTINUITY..........................9STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND...................9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS...........10
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP......................10
SPECIAL TOOLS
WIRING/TERMINAL....................10
CONNECTOR
REMOVAL.............................11
INSTALLATION.........................11
DIODE
REMOVAL.............................14
INSTALLATION.........................14
TERMINAL
REMOVAL.............................14
INSTALLATION.........................14
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 15
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are
designed to provide information regarding the vehi-
cles wiring content. In order to effectively use the
wiring diagrams to diagnose and repair
DaimlerChrysler Corporation vehicles, it is important
to understand all of their features and characteris-
tics.
Diagrams are arranged such that the power (B+)
side of the circuit is placed near the top of the page,
and the ground (B-) side of the circuit is placed near
the bottom of the page (Fig. 1).
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition (Fig. 2).Components are shown two ways. A solid line
around a component indicates that the component is
complete. A dashed line around the component indi-
cates that the component is being shown is not com-
plete. Incomplete components have a reference
number to indicate the page where the component is
shown complete.
It is important to realize that no attempt is made
on the diagrams to represent components and wiring
as they appear on the vehicle. For example, a short
piece of wire is treated the same as a long one. In
addition, switches and other components are shown
as simply as possible, with regard to function only.
SYMBOLS
International symbols are used throughout the wir-
ing diagrams. These symbols are consistent with
those being used around the world (Fig. 3).
WJ8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.Connector, ground, and splice indexes are provided.
Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
appropriate index for the proper figure number. For
items that are not shown in this section N/S is placed
in the Fig. column.
CONNECTORS
CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
A/C Compressor Clutch BK At A/C Compressor 9, 13
A/C Pressure Transducer BK Right Front of Engine Compartment 3, 4, 5
Accelerator Pedal Position
Sensor (Diesel)BK Rear of Engine Compartment Near
Fuel/Water Seperator7
Adjustable Pedals Module
(Except Built-up Export)GN Above Drivers Control Pedals N/S
Adjustable Pedals Motor/
Sensor Assembly (Except
Built-up Export)Above Drivers Control Pedals N/S
Adjustable Pedals Switch WT Drivers Lower Kick Panel 21
Airbag Control Module (ORC)
C1YL Below Center Floor Console, Near
Park Brake19, 20, 21, 22
Airbag Control Module (ORC)
C2YL Below Center Floor Console, Near
Park Brake19, 20, 21, 22
Ambient Temperature Sensor BK On Radiator Center Support 5
Antenna Module (Built-up-
export)WT Above Right Quarter Window N/S
Ash Receiver Lamp BK Below Cigarette Lighter 19, 20
Automatic Day/Night Mirror BK In Front of Rear View Mirror N/S
Automatic Headlamp Light
Sensor/VTSS LEDBK Near Left Instrument Panel Speaker 19, 20
Automatic Zone Control
Module - C1 (AZC)WT Left Side of HVAC Housing N/S
Automatic Zone Control
Module - C2 (AZC)WT Left Side of HVAC Housing N/S
Battery Temperature Sensor BK Below Battery Tray 4, 5
Blower Motor BK Behind Right Hand Side of
Instrument PanelN/S
WJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
CIGAR LIGHTER OUTLET
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
CIGAR LIGHTER OUTLET DOOR SPRING
REMOVAL.............................3
INSTALLATION..........................3
IOD FUSE
DESCRIPTION..........................3
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
JUNCTION BLOCK
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
POWER DISTRIBUTION CENTER
DESCRIPTION..........................7
OPERATION............................8
REMOVAL.............................8
DISASSEMBLY
POWER DISTRIBUTION CENTER
DISASSEMBLY........................9ASSEMBLY
POWER DISTRIBUTION CENTER
ASSEMBLY..........................11
INSTALLATION.........................12
POWER OUTLET
DESCRIPTION - FRONT POWER OUTLET....12
OPERATION - FRONT POWER OUTLET......12
DIAGNOSIS AND TESTING - POWER OUTLET . 12
REMOVAL.............................13
INSTALLATION.........................13
POWER OUTLET RELAY
DESCRIPTION.........................13
OPERATION...........................14
DIAGNOSIS AND TESTING - POWER OUTLET
RELAY..............................14
REMOVAL.............................15
INSTALLATION.........................15
IOD WIRE HARNESS CONNECTOR
DESCRIPTION.........................15
OPERATION...........................15
FUSE COVER
REMOVAL.............................16
INSTALLATION.........................16
REAR POWER OUTLET
DESCRIPTION - REAR POWER OUTLET.....16
OPERATION - REAR POWER OUTLET.......17
DIAGNOSIS AND TESTING - REAR POWER
OUTLET............................17
REMOVAL.............................17
INSTALLATION.........................18
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Power Distribution Center (PDC)
²Junction Block (JB)
²Power Outlets
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses²Circuit splice blocks
²Flashers
²Fusible links
²Standard and Micro-Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components. Refer to Wir-
ing Diagrams for complete circuit diagrams.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the standard and optional factory-in-
stalled electrical and electronic powertrain, chassis,
safety, security, comfort and convenience systems. At
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 1

ENGINE
TABLE OF CONTENTS
page page
ENGINE - 4.0L............................ 1ENGINE - 4.7L........................... 61
ENGINE - 4.0L
TABLE OF CONTENTS
page page
ENGINE - 4.0L
DESCRIPTION..........................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE..............8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......8
DIAGNOSIS AND TESTINGÐREAR SEAL
AREA LEAKS..........................9
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS..........9
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........10
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................10
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................10
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............11
REMOVAL.............................11
INSTALLATION.........................13
SPECIFICATIONS
ENGINE - 4.0L........................14
TORQUE - 4.0L ENGINE................17
AIR CLEANER ELEMENT
REMOVAL - 4.0L........................18
INSTALLATION - 4.0L....................19
AIR CLEANER HOUSING
REMOVAL - 4.0L........................19
INSTALLATION - 4.0L....................19CYLINDER HEAD
DESCRIPTION.........................19
REMOVAL.............................19
CLEANING............................21
INSPECTION..........................21
INSTALLATION.........................21
CYLINDER HEAD COVER(S)
DESCRIPTION.........................22
REMOVAL.............................22
CLEANING............................23
INSPECTION..........................23
INSTALLATION.........................23
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................23
STANDARD PROCEDURE - VALVE SERVICE . . 23
REMOVAL.............................25
INSTALLATION.........................25
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................26
CLEANING............................26
INSPECTION..........................27
INSTALLATION.........................27
VALVE STEM SEALS
DESCRIPTION.........................27
VALVE SPRINGS
DESCRIPTION.........................28
STANDARD PROCEDURE - VALVE SPRING
TENSION TEST.......................28
REMOVAL.............................28
INSTALLATION.........................29
ENGINE BLOCK
CLEANING............................30
INSPECTION..........................30
CAMSHAFT & BEARINGS
DESCRIPTION.........................30
WJENGINE 9 - 1

ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DESCRIPTIONÐ4.7L ENGINE.............63
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........64
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........65
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............66
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION.............67
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE.............68
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......69
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........70
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........70
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........70
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............71
REMOVAL.............................71
INSTALLATION.........................73
SPECIFICATIONS
4.7L ENGINE.........................74
SPECIFICATIONS - 4.7L H.O. ENGINE.....77
TORQUE............................79
SPECIAL TOOLS
4.7L ENGINE.........................80
AIR CLEANER ELEMENT
REMOVAL - 4.7L........................83
INSTALLATION - 4.7L....................83
AIR CLEANER HOUSING
REMOVAL - 4.7L........................84
INSTALLATION - 4.7L....................84
CYLINDER HEAD - LEFT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........84
DESCRIPTION - VALVE GUIDES..........84
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................84
DIAGNOSIS AND TESTINGÐCYLINDER
HEAD GASKET.......................85
REMOVAL.............................85
CLEANING............................86
INSPECTION..........................87INSTALLATION.........................87
CAMSHAFT(S) - LEFT
DESCRIPTION.........................88
REMOVAL.............................89
INSTALLATION.........................90
CYLINDER HEAD COVER(S) - LEFT
DESCRIPTION.........................93
REMOVAL - LEFT SIDE..................93
CLEANING............................93
INSTALLATIONÐLEFT SIDE...............93
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................94
STANDARD PROCEDUREÐREFACING......94
REMOVAL.............................94
INSTALLATION.........................95
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION.........................96
REMOVAL.............................96
INSTALLATION.........................96
VALVE SPRINGS
DESCRIPTION.........................97
VALVE STEM SEALS
DESCRIPTION.........................97
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........97
DESCRIPTION - VALVE GUIDES..........97
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐCYLINDER
HEAD GASKET.......................97
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................98
REMOVAL.............................98
CLEANING............................99
INSPECTION..........................99
INSTALLATION.........................99
CAMSHAFT(S) - RIGHT
DESCRIPTION........................100
REMOVAL............................100
INSTALLATION........................102
CYLINDER HEAD COVER(S) - RIGHT
DESCRIPTION........................104
REMOVAL - RIGHT SIDE................104
CLEANING...........................104
INSTALLATION - RIGHT SIDE.............104
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................104
STANDARD PROCEDUREÐREFACING.....105
REMOVAL............................105
INSTALLATION........................106
WJENGINE - 4.7L 9 - 61

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION - EXHAUST SYSTEM.........1
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM.............................3
SPECIFICATIONS
TORQUE.............................3
CATALYTIC CONVERTER - 4.0L
DESCRIPTION - CATALYTIC CONVERTER
4.0L ENGINE..........................4
REMOVAL.............................4
INSPECTION...........................5
INSTALLATION..........................5
CATALYTIC CONVERTER - 4.7L
DESCRIPTION - CATALYTIC CONVERTER.....6
REMOVAL.............................6
INSPECTION...........................7
INSTALLATION..........................7EXHAUST PIPE - 4.0L
REMOVAL.............................8
INSPECTION...........................8
INSTALLATION..........................8
EXHAUST PIPE - 4.7L
REMOVAL.............................10
INSPECTION..........................10
INSTALLATION.........................10
HEAT SHIELDS
DESCRIPTION.........................12
MUFFLER
DESCRIPTION.........................12
REMOVAL.............................12
INSTALLATION.........................12
TAILPIPE
DESCRIPTION.........................13
OPERATION...........................13
EXHAUST SYSTEM
DESCRIPTION - EXHAUST SYSTEM
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan heat shields. Light overspray near the
edges is permitted. Application of coating will result
in excessive floor pan temperatures and objection-
able fumes.
The exhaust system uses a single muffler with a
welded tailpipe.The 50 State Emissions vehicles use two mini cat-
alytic converters inline with the exhaust pipe below
the exhaust manifolds.
The exhaust manifolds are equipped with ball
flange outlets to assure a tight seal and strain free
connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it may amplify objec-
tionable noises originating from the engine or body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
The basic exhaust system consists of exhaust man-
ifold(s), exhaust pipe with oxygen sensors, catalytic
converter(s), heat shield(s), muffler and tailpipe (Fig.
1) and (Fig. 2).
WJEXHAUST SYSTEM 11 - 1

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT ABSORBER
REMOVAL.............................1
INSTALLATION..........................1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
REAR ABSORBER
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................4
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE.............4
FRAME DIMENSIONS...................4
FRONT SKID PLATE
REMOVAL.............................7INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
FUEL TANK SKID PLATE
DESCRIPTION..........................7
REAR TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
TRAILER HITCH
REMOVAL.............................8
INSTALLATION..........................8
TRANSFER CASE SKID PLATE
REMOVAL.............................8
INSTALLATION..........................8
FRONT ABSORBER
REMOVAL
(1) Remove front fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL).
(2) Remove the retainer attaching the absorber to
the fascia.
(3) Separate the absorber from the fascia.
INSTALLATION
(1) Position the absorber on the fascia.
(2) Install the retainer attaching the absorber to
the fascia.
(3) Install front fascia. Refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
FRONT FASCIA
REMOVAL
(1) Raise and support vehicle.
(2) Turn front wheels to access rivets and remove
plastic rivets attaching fascia to wheel liner.
(3) Remove bolts attaching fascia to fender (Fig. 1).(4) Remove plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(5) Disengage fog lamp connectors, if equipped.
(6) Remove screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(7) Slide fascia forward to separate from vehicle.
INSTALLATION
(1) Slide fascia onto vehicle engaging fascia with
tabs on bottom of front fenders.
(2) Install screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(3) Install bolts attaching fascia to fender (Fig. 1).
(4) Engage fog lamp connectors, if equipped.
(5) Install plastic rivets attaching fascia to wheel
liner.
(6) Install plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(7) Remove supports and lower vehicle.
WJFRAME & BUMPERS 13 - 1