2002 JEEP GRAND CHEROKEE key

SPLICE
NUMBERLOCATION FIG.
S326 Near T/O for C200 34, 35
S327 Near T/O for c307 34, 35
S328 In Sill Trough Near T/O for G300 34
S329 In Sill Trough Near T/O for G300 34
S330 Near T/O for G300 34
S331 In Sill Trough Near T/O for C303 34, 36
S332 In Sill Trough Near T/O for C303 34, 36
S333 Near T/O for Power Amplifiers 36
S334 In T/O for Power Amplifier - C2 34
S335 Near T/O for C314 36
S336 Near T/O for Driver Power Window Motor 24, 25
S338 Near T/O for Passenger Power Window Motor 26, 27
S339 Near T/O for Passenger Power Window Motor 26 27
S340 In T/O for Passenger Door Module - C1 26, 27
S341 Near T/O for C306 N/S
S345 Near T/O for Sunroof Switch 32
S346 Near T/O for Left Visor/Vanity Lamp 32
S347 Near T/O for Left Visor/Vanity Lamp 32
S348 Near T/O for Automatic Day/Night Mirror 32
S349 Near T/O for Automatic Day/Night Mirror 32
S351 Near T/O for Seat Belt Switch N/S
S352 Near T/O for Seat Belt Switch N/S
S353 Near T/O for Driver Lumbar Switch N/S
S355 Near T/O for C304 and C306 N/S
S356 In T/O for Left Rear Door Lock Motor/Ajar Switch 28
S357 In T/O for Right Rear Door Lock Motor/Ajar Switch 29
S358 Near Left B Pillar Sill Trough 35
S359 Near T/O for C302 34
S360 In T/O for C302 N/S
S362 In T/O for C200 34
S363 In T/O for C200 34
S364 Near B Pillar Sill Trough 36
S365
JapanNear T/O for Remote Keyless Entry Module 24, 25
S366 Near T/O for Junction Block C1 N/S
S367 (RHD) Near T/O for C310 N/S
S368 Near T/O for Power Amplifier - C1 34
S369 Near T/O for Left Visor Vanity Lamp N/S
S370 Near T/O for Sunroof Module 32
S400 Near Rear Window Defogger Ground Connector 38
S401 Near Rear Window Defogger Ground Connector 38
S402 Near T/O for Liftgate Flip-Up Ajar Switch 38
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(e) If end play is not within specification, inspect
crankshaft thrust faces for wear. If no wear is
apparent, replace the thrust bearing and measure
end play. If end play is still not within specifica-
tion, replace the crankshaft.
(11) If the crankshaft was removed, install the
crankshaft into the cylinder block.
(12) Install main bearing cap brace tighten nuts to
47 N´m (35 ft. lbs.) torque.
(13) Install oil pump assy. and tighten attaching
bolts to 23 N´m (17 ft. lbs.)
(14) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(15) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(16) Lower the vehicle.
(17) Install the spark plugs. Tighten the plugs to
37 N´m (27 ft. lbs.) torque.
(18) Fill the oil pan with engine oil to the full
mark on the dipstick level.
(19) Connect negative cable to battery.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
This procedure is done with the timing case cover
installed.
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(3) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(4) Remove the radiator shroud.
(5) Carefully remove the oil seal. Make sure seal
bore is clean.
INSTALLATION
This procedure is done with the timing case cover
installed.
(1) Position the replacement oil seal on Timing
Case Cover Alignment and Seal Installation Tool
6139 with seal open end facing inward. Apply a light
film of Perfect Seal, or equivalent, on the outside
diameter of the seal. Lightly coat the crankshaft with
engine oil.
(2) Position the tool and seal over the end of the
crankshaft and insert a draw screw tool into Seal
Installation Tool 6139 (Fig. 50). Tighten the nut
against the tool until it contacts the cover.
(3) Remove the tools. Apply a light film of engine
oil on the vibration damper hub contact surface of
the seal.
(4) Apply MopartSilicone Rubber Adhesive Seal-
ant to the keyway in the crankshaft and insert the
key. With the key inserted in the keyway in the
crankshaft, install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(5) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install the radiator shroud.
(7) Connect negative cable to battery.
Fig. 49 Crankshaft End Play Measurement
1 - DIAL INDICATOR
2 - CRANKSHAFT
Fig. 50 Timing Case Cover Oil Seal Installation
1 - SEAL INSTALLATION TOOL
2 - DRAW SCREW TOOL
WJENGINE - 4.0L 9 - 41
CRANKSHAFT MAIN BEARINGS (Continued)

VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) and fan shroud.
(3) Remove the vibration damper retaining bolt
and washer.
(4) Use Vibration Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fig. 70).
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant to the keyway in the crankshaft and insert the
key. With the key in position, align the keyway on
the vibration damper hub with the crankshaft key
and tap the damper onto the crankshaft.
(2) Install the vibration damper retaining bolt and
washer.
(3) Tighten the damper retaining bolt to 108 N´m
(80 ft. lbs.) torque.
(4) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION) and fan shroud.
(5) Connect negative cable to battery.
STRUCTURAL SUPPORT
REMOVAL
The engine bending braces are used to add
strength to the powertrain and to address some
minor NVH concerns.
Fig. 68 Compression Ring Installation
1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED
Fig. 69 Ring Gap Orientation
1 - TOP COMPRESSION RING
2 - BOTTOM COMPRESSION RING
3 - TOP OIL CONTROL RAIL
4 - OIL RAIL SPACER
5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
Fig. 70 Vibration Damper Removal Tool 7697
1 - VIBRATION DAMPER REMOVAL TOOL
2 - WRENCH
WJENGINE - 4.0L 9 - 49
PISTON RINGS (Continued)

(1) Install a new crankshaft oil seal in the timing
case cover. The open end of the seal should be toward
the inside of the cover. Support the cover at the seal
area while installing the seal. Force it into position
with Seal Installation Tool 6139.
(2) Position the gasket on the cylinder block.
(3) Position the timing case cover on the oil pan
gasket and the cylinder block.
(4) Insert Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 87).
(5) Install the timing case cover-to-cylinder block
and the oil pan-to-timing case cover bolts.
(6) Tighten the 1/4 inch cover-to-block bolts to 7
N´m (60 in. lbs.) torque. Tighten the 5/16 inch front
cover-to-block bolts to 22 N´m (192 in. lbs.) torque.
Tighten the oil pan-to-cover 1/4 inch bolts to 9.5 N´m
(84 in. lbs.) torque.(7) Remove the cover alignment tool.
(8) Apply a light film of engine oil on the vibration
damper hub contact surface of the seal.
(9) Apply MopartSilicone Rubber Adhesive Seal-
ant to the keyway in the crankshaft and insert the
key. With the key inserted in the keyway in the
crankshaft, install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION) (if equipped) and
generator bracket assembly.
(11) Install the engine fan, hub assembly and
shroud (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(12) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Connect negative cable to battery.
Fig. 85 EXHAUST MANIFOLDS 4.0L ENGINE
Fig. 86 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEYFig. 87 Timing Case Cover Alignment
1 - TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
WJENGINE - 4.0L 9 - 59
TIMING BELT / CHAIN COVER(S) (Continued)

TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fan and shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the crankshaft vibration damper (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(5) Remove the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Rotate crankshaft until the ª0º timing mark is
closest to and on the center line with camshaft
sprocket timing mark (Fig. 88).
(7) Remove the oil slinger from the crankshaft.
(8) Remove the camshaft sprocket bolt and washer
(Fig. 89).
(9) Remove the crankshaft sprocket, camshaft
sprocket and timing chain as an assembly.
(10) Installation of the timing chain with the tim-
ing marks on the crankshaft and camshaft sprockets
properly aligned ensures correct valve timing. A worn
or stretched timing chain will adversely affect valvetiming. If the timing chain deflects more than 12.7
mm (1/2 inch) replace it.
INSTALLATION
Assemble the timing chain, crankshaft sprocket
and camshaft sprocket with the timing marks
aligned (Fig. 88).
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant to the keyway in the crankshaft and insert the
key. With the key in the keyway on the crankshaft,
install the assembly on the crankshaft and camshaft.
(2)
Install the camshaft sprocket bolt and washer
(Fig. 89). Tighten the bolt to 68 N´m (50 ft. lbs.) torque.
(3) To verify correct installation of the timing
chain, rotate the crankshaft 2 revolutions. The cam-
shaft and crankshaft sprocket timing mark should
align (Fig. 88).
(4) Install the crankshaft oil slinger.
(5) Replace the oil seal in the timing case cover
(Refer to 9 - ENGINE/ENGINE BLOCK/CRANK-
SHAFT OIL SEAL - FRONT - REMOVAL).
(6) Install the timing case cover and gasket (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT /
CHAIN COVER(S) - INSTALLATION).
(7) With the key installed in the crankshaft key-
way, install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(8) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the fan, hub assembly and shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(10) Connect negative cable to battery.
Fig. 88 CrankshaftÐCamshaft Alignment
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
Fig. 89 Camshaft Sprocket and Thrust Plate
1 - CAMSHAFT
2 - CAMSHAFT SPROCKET W/INTEGRAL KEY
3 - BOLT AND WASHER
4 - THRUST PLATE
9 - 60 ENGINE - 4.0LWJ

(3) Remove crankshaft damper bolt.
(4) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 79).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512±A as follows, The
nut is threaded onto the shaft first. Then the roller
bearing is placed onto the threaded rod (The hard-
ened bearing surface of the bearingMUSTface the
nut). Then the hardened washer slides onto the
threaded rod (Fig. 80). Once assembled coat the
threaded rod's threads with MopartNickel Anti-
Seize or (Loctite No. 771).
(3) Using Special Tool 8512A, press damper onto
crankshaft (Fig. 81).
(4) Install then tighten crankshaft damper bolt to
175 N´m (130 ft. lbs.).(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Connect negative cable to battery.
Fig. 79 Crankshaft DamperÐRemoval
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 80 Proper Assembly Method for Special Tool
8512±A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 81 Crankshaft Damper Installation
1 - SPECIAL TOOL 8512A
WJENGINE - 4.7L 9 - 123
VIBRATION DAMPER (Continued)

STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa   34 kPa (49.2 psi   5 psi).
TORQUE - FUEL DELIVERY
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket Mounting Nuts
(without adjustable pedals)12  2 - 105  20
Fuel Filter/Fuel Press. Reg. Bolts 3 - 26
Fuel Hose Clamps 3 - 26
Fuel Injector Rail Mounting Bolts -4.0L Engine 11 - 100
Fuel Injector Rail Mounting Bolts -4.7L V-8
Engine11 - 100
Fuel Pump Module Locknut 74 55 -
Fuel Tank Filler Tube-to-Body Mounting Bolts 2 - 15
Fuel Tank-to-Body Mounting Bolts 88 65 -
Fuel Tank Support Bracket Bolts (large brackets) 88 65 -
Fuel Tank Support Bracket Bolts (small bracket) 5 - 45
Fuel Tank Support Bracket Nuts (large brackets) 61 45 -
Fuel Tank Heat Shield Nuts (shield-to-tank) 9 - 85
Fuel Tank Heat Shield Nuts (shield-to-body) 3 - 25
14 - 4 FUEL DELIVERYWJ
FUEL DELIVERY (Continued)

(5) Connect (-) and (+) test cable leads into LCS
adapter receptacles. Use10 amp (10A +)receptacle
and common (-) receptacles.
(6) Gain access to MAIN MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Using left/right arrow keys, highlight CHAN-
NEL 1 function on DRB screen.
(9) Press ENTER three times.
(10) Using up/down arrow keys, highlight RANGE
on DRB screen (screen will default to 2 amp scale).
(11) Press ENTER to change 2 amp scale to 10
amp scale.This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Distribution Center
(PDC).
(13) Remove fuel pump relay from PDC. Refer to
label on PDC cover for relay location.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type±3.
(14) If equipped withtype±1 relay(Fig. 9), attach
test leads from LCS adapter into PDC relay cavities
number 30 and 87. For location of these cavities,
refer to numbers stamped to bottom of relay (Fig. 9).
(15) If equipped withtype±2 relay(Fig. 10),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 10).
(16) If equipped withtype±3 relay(Fig. 11),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 11).
(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the FuelPump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
Fig. 9 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 10 FUEL PUMP RELAY - TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
14 - 10 FUEL DELIVERYWJ
FUEL PUMP (Continued)