2002 JEEP GRAND CHEROKEE 8W electric

HORN SWITCH
DESCRIPTION
A center-blow, normally open, resistive membrane-
type horn switch is secured in a plastic tray that is
inserted in a pocket sewn on the front of the driver
side airbag retainer strap. The horn switch is con-
cealed behind the driver side airbag module trim
cover in the center of the steering wheel. The switch
consists of two plastic membranes, one that is flat
and one that is slightly convex. These two mem-
branes are secured to each other around the perime-
ter. Inside the switch, the centers of the facing
surfaces of these membranes each has a grid made
with an electrically conductive material applied to it.
One of the grids is connected to a circuit that pro-
vides it with continuity to ground at all times. The
grid of the other membrane is connected to the horn
relay control circuit.
The steering wheel and steering column must be
properly grounded in order for the horn switch to
function properly. The horn switch and plastic tray
are serviced as a unit. If the horn switch is damaged
or faulty, or if the driver side airbag is deployed, the
horn switch and tray must be replaced as a unit.
OPERATION
When the center area of the driver side airbag trim
cover is depressed, the electrically conductive grids
on the facing surfaces of the horn switch membranes
contact each other, closing the switch circuit. The
completed horn switch circuit provides a ground for
the control coil side of the horn relay, which activates
the relay. When the horn switch is released, the
resistive tension of the convex membrane separates
the two electrically conductive grids and opens the
switch circuit.
DIAGNOSIS AND TESTING - HORN SWITCH
For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable. Remove the steering column opening cover
from the instrument panel.
(2) Check for continuity between the metal steer-
ing column jacket and a good ground. There should
be continuity. If OK, go to Step 3. If not OK, refer to
Steering, Column for proper installation of the steer-
ing column.
(3) Remove the driver side airbag module from the
steering wheel. Disconnect the horn switch wire har-
ness connectors from the driver side airbag module.
(4) Remove the horn relay from the Power Distri-
bution Center (PDC). Check for continuity between
the steering column half of the horn switch feed wire
harness connector and a good ground. There should
be no continuity. If OK, go to Step 5. If not OK,
repair the shorted horn relay control circuit to the
horn relay in the PDC as required.
(5) Check for continuity between the steering col-
umn half of the horn switch feed wire harness con-
nector and the horn relay control circuit cavity for
the horn relay in the PDC. There should be continu-
ity. If OK, go to Step 6. If not OK, repair the open
horn relay control circuit to the horn relay in the
PDC as required.
Fig. 3 Power Distribution Center
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
8H - 6 HORNWJ
HORN RELAY (Continued)

(6) Check for continuity between the horn switch
feed wire and the horn switch ground wire on the
driver side airbag module. There should be no conti-
nuity. If OK, go to Step 7. If not OK, replace the
faulty horn switch.
(7) Depress the center of the driver side airbag
module trim cover and check for continuity between
the horn switch feed wire and the horn switch
ground wire on the driver side airbag module. There
should now be continuity. If not OK, replace the
faulty horn switch.
REMOVAL
WARNING:
²ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
²THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the trim cover from the driver side air-
bag module. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - REMOVAL) for the
procedure.
(3) Remove the horn switch and tray as a unit
from the pouch on the retaining strap of the driver
side airbag module (Fig. 4).
INSTALLATION
WARNING:
²ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO ELECTRICAL, RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.²THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Install the horn switch and tray as a unit into
the pouch on the retaining strap of the driver side
airbag module. Be certain that the tray is facing the
airbag module, that the horn switch is facing the
trim cover, that the horn switch feed wire is on the
left, and that the horn switch ground wire is on the
right.
(2) Install the trim cover onto the driver side air-
bag module. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - INSTALLATION) for
the procedure.
(3) Reconnect the battery negative cable.
Fig. 4 Horn Switch Remove/Install
1 - HORN SWITCH GROUND WIRE EYELET
2 - HORN SWITCH
3 - AIRBAG RETAINING STRAP
4 - POUCH
5 - DRIVER SIDE AIRBAG MODULE (TRIM COVER REMOVED)
6 - TRAY
7 - HORN SWITCH FEED WIRE CONNECTOR
WJHORN 8H - 7
HORN SWITCH (Continued)

IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION..........................1
OPERATION............................1
SPECIFICATIONS
ENGINE FIRING ORDER - 4.0L 6-CYLINDER
ENGINE..............................2
ENGINE FIRING ORDERÐ4.7L V-8 ENGINE . . 2
IGNITION COIL RESISTANCE - 4.0L ENGINE . 2
IGNITION COIL RESISTANCEÐ4.7L V-8
ENGINE..............................2
IGNITION TIMING......................2
SPARK PLUGS........................3
TORQUE - IGNITION SYSTEM............3
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT.............3
OPERATION
OPERATION - PCM OUTPUT.............3
OPERATION - ASD SENSE - PCM INPUT....4
REMOVAL.............................4
INSTALLATION..........................4
CAMSHAFT POSITION SENSOR
DESCRIPTION
DESCRIPTION - 4.0L....................4
DESCRIPTION - 4.7L....................5
OPERATION
OPERATION - 4.0L.....................5
OPERATION - 4.7L.....................5
REMOVAL
REMOVAL - 4.0L.......................6
REMOVAL - 4.7L.......................7INSTALLATION
INSTALLATION - 4.0L...................8
INSTALLATION - 4.7L...................9
COIL RAIL
DESCRIPTION..........................9
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................11
IGNITION COIL
DESCRIPTION.........................11
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................12
IGNITION COIL CAPACITOR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................13
KNOCK SENSOR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................15
SPARK PLUG
DESCRIPTION.........................15
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS.........................15
REMOVAL.............................18
CLEANING............................18
INSTALLATION.........................18
IGNITION CONTROL
DESCRIPTION
Two different ignition systems are used. One type
of system is for the 4.0L 6±cylinder engine. The other
is for the 4.7L V-8 engine.
OPERATION
The 4.0L 6±cylinder engine uses a one-piece coil
rail containing three independent coils. Although cyl-
inder firing order is the same as 4.0L engines of pre-
vious years, spark plug firing is not. The 3 coils dual-
fire the spark plugs on cylinders 1±6, 2±5 and/or 3±4.
When one cylinder is being fired (on compressionstroke), the spark to the opposite cylinder is being
wasted (on exhaust stroke). The one-piece coil bolts
directly to the cylinder head. Rubber boots seal the
secondary terminal ends of the coils to the top of all
6 spark plugs. One electrical connector (located at
the rear end of the coil rail) is used for all three coils.
The 4.7L V-8 engine uses 8 dedicated and individ-
ually fired coil for each spark plug. Each coil is
mounted directly to the top of each spark plug. A sep-
arate electrical connector is used for each coil.
Because of coil design, spark plug cables (second-
ary cables) are not used on either engine. Adistrib-
utor is not usedwith either the 4.0L or 4.7L
engines.
WJIGNITION CONTROL 8I - 1

REMOVAL
REMOVAL - 4.0L
The Camshaft Position Sensor (CMP) on the 4.0L
6±cylinder engine is bolted to the top of the oil pump
drive shaft assembly (Fig. 6). The sensor and drive
shaft assembly is located on the right side of the
engine near the oil filter (Fig. 7).
The rotational position of oil pump drive deter-
mines fuel synchronization only. It does not deter-
mine ignition timing.
NOTE: Do not attempt to rotate the oil pump drive
to modify ignition timing.
Two different proceduresare used for removal
and installation. The first procedure will detail
removal and installation of the sensor only. The sec-
ond procedure will detail removal and installation of
the sensor and oil pump drive shaft assembly. The
second procedure is to be used if the engine has been
disassembled.
An internal oil seal is used in the drive shaft hous-
ing that prevents engine oil at the bottom of the sen-
sor. The seal is not serviceable.
SENSOR ONLY - 4.0L
(1) Disconnect electrical connector at CMP sensor
(Fig. 7).
(2) Remove 2 sensor mounting bolts (Fig. 6) or
(Fig. 7).
(3) Remove sensor from oil pump drive.
OIL PUMP DRIVE AND SENSOR - 4.0L
If the CMP and oil pump drive are to be
removed and installed, do not allow engine
crankshaft or camshaft to rotate. CMP sensor
relationship will be lost.
(1) Disconnect electrical connector at CMP sensor
(Fig. 7).
(2) Remove 2 sensor mounting bolts (Fig. 6) or
(Fig. 7).
(3) Remove sensor from oil pump drive.
(4) Before proceeding to next step, mark and note
rotational position of oil pump drive in relationship
to engine block. After installation, the CMP sensor
should face rear of engine 0É.
(5) Remove hold-down bolt and clamp (Fig. 7).
Fig. 5 CMP Sensor and TonewheelÐ4.7L Engine
1 - NOTCHES
2 - RIGHT CYLINDER HEAD
3 - CAMSHAFT POSITION SENSOR
4 - TONEWHEEL
Fig. 6 CMP and Oil Pump Drive Shaft - 4.0L Engine
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
8I - 6 IGNITION CONTROLWJ
CAMSHAFT POSITION SENSOR (Continued)

(6) While pulling assembly from engine, note direc-
tion and position of pulse ring (Fig. 6). After removal,
look down into top of oil pump and note direction and
position of slot at top of oil pump gear.
(7) Remove and discard old oil pump drive-to-en-
gine block gasket.
REMOVAL - 4.7L
The Camshaft Position Sensor (CMP) on the 4.7L
V±8 engine is bolted to the front/top of the right cyl-
inder head (Fig. 10).
It is easier to remove/install sensor from under
vehicle.
(1) Raise and support vehicle.
(2) Disconnect electrical connector at CMP sensor
(Fig. 10).
(3) Remove sensor mounting bolt (Fig. 10).
(4) Carefully pry sensor from cylinder head in a
rocking action with two small screwdrivers.Some
4.7L engines are equipped with a sensor spacer
shim. If equipped, this shim will be located at
sensor bolt hole between cylinder head and
sensor mounting tang (TSB W08±18±00). Save
this shim for sensor installation.
(5) Check condition of sensor o-ring.
Fig. 7 CMP Location - 4.0L Engine
1 - OIL FILTER
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
5 - MOUNTING BOLTS (2)
6 - ELEC. CONNECTOR
Fig. 8 CMP Pulse Ring Alignment - 4.0L Engine
1 - PULSE RING (SHUTTER)
2 - TOOTHPICK
3 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
Fig. 9 Align Timing Marks - 4.0L Engine
1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK
WJIGNITION CONTROL 8I - 7
CAMSHAFT POSITION SENSOR (Continued)

INSTALLATION
INSTALLATION - 4.0L
SENSOR ONLY - 4.0L
The Camshaft Position Sensor (CMP) on the 4.0L
6±cylinder engine is bolted to the top of the oil pump
drive shaft assembly (Fig. 6). The sensor and drive
shaft assembly is located on the right side of the
engine near the oil filter (Fig. 7).
(1) Install sensor to oil pump drive.
(2) Install 2 sensor mounting bolts and tighten to
2 N´m (15 in. lbs.) torque.
(3) Connect electrical connector to CMP sensor.
OIL PUMP DRIVE AND SENSOR - 4.0L
(1) Clean oil pump drive mounting hole area of
engine block.
(2) Install new oil pump drive-to-engine block gas-
ket.
(3) Temporarily install a toothpick or similar tool
through access hole at side of oil pump drive housing.
Align toothpick into mating hole on pulse ring (Fig.
8).(4) Install oil pump drive into engine while align-
ing into slot on oil pump. Rotate oil pump drive back
to its original position and install hold-down clamp
and bolt. Finger tighten bolt. Do not do a final tight-
ening of bolt at this time.
(5) If engine crankshaft or camshaft has been
rotated, such as during engine tear-down, CMP sen-
sor relationship must be reestablished.
(a) Remove ignition coil rail assembly. Refer to
Ignition Coil Removal/Installation.
(b) Remove cylinder number 1 spark plug.
(c) Hold a finger over the open spark plug hole.
Rotate engine at vibration dampener bolt until
compression (pressure) is felt.
(d) Slowly continue to rotate engine. Do this
until timing index mark on vibration damper pul-
ley aligns with top dead center (TDC) mark (0
degree) on timing degree scale (Fig. 9). Always
rotate engine in direction of normal rotation. Do
not rotate engine backward to align timing marks.
(e) Install oil pump drive into engine while
aligning into slot on oil pump. If pump drive will
not drop down flush to engine block, the oil pump
slot is not aligned. Remove oil pump drive and
align slot in oil pump to shaft at bottom of drive.
Install into engine. Rotate oil pump drive back to
its original position and install hold-down clamp
and bolt. Finger tighten bolt. Do not do a final
tightening of bolt at this time.
(f) Remove toothpick from housing.
(6) Install sensor to oil pump drive. After installa-
tion, the CMP sensor should face rear of engine 0É.
(7) Install 2 sensor mounting bolts and tighten to
2 N´m (15 in. lbs.) torque.
(8) Connect electrical connector to CMP sensor.
(9) If removed, install spark plug and ignition coil
rail.
To verify correct rotational position of oil pump
drive, the DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
(10) Connect DRB scan tool to data link connector.
The data link connector is located in passenger com-
partment, below and to left of steering column.
(11) Gain access to SET SYNC screen on DRB.
(12) Follow directions on DRB screen and start
engine. Bring to operating temperature (engine must
be in ªclosed loopº mode).
(13) With engine running atidle speed, the words
IN RANGE should appear on screen along with 0É.
This indicates correct position of oil pump drive.
Fig. 10 CMP LocationÐ4.7L Engine
1 - RIGHT CYLINDER HEAD
2 - CAMSHAFT POSITION SENSOR
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
8I - 8 IGNITION CONTROLWJ
CAMSHAFT POSITION SENSOR (Continued)

(14) If a plus (+) or a minus (-) is displayed next to
degree number, and/or the degree displayed is not
zero, loosen but do not remove hold-down clamp bolt.
Rotate oil pump drive until IN RANGE appears on
screen. Continue to rotate oil pump drive until
achieving as close to 0É as possible.
The degree scale on SET SYNC screen of DRB is
referring to fuel synchronization only.It is not
referring to ignition timing.Because of this, do
not attempt to adjust ignition timing using this
method. Rotating oil pump drive will have no effect
on ignition timing. All ignition timing values are con-
trolled by powertrain control module (PCM).
(15) Tighten hold-down clamp bolt to 23 N´m (17
ft. lbs.) torque.
INSTALLATION - 4.7L
The Camshaft Position Sensor (CMP) on the 4.7L
V±8 engine is bolted to the front/top of the right cyl-
inder head (Fig. 10).
(1) Clean out machined hole in cylinder head.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into cylinder head with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder head.
If sensor is not flush, damage to sensor mounting
tang may result.
(4) Install mounting bolt and tighten to 12 N´m
(106 in. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
COIL RAIL
DESCRIPTION
A one-piece coil rail assembly containing three
individual coils is used on the 4.0L 6±cylinder engine
(Fig. 11). The coil rail must be replaced as one
assembly. The bottom of the coil is equipped with 6
individual rubber boots (Fig. 11) to seal the 6 spark
plugs to the coil. Inside each rubber boot is a spring.
The spring is used for a mechanical contact between
the coil and the top of the spark plug. These rubber
boots and springs are a permanent part of the coil
and are not serviced separately.
(1) The coil is bolted directly to the cylinder head
(Fig. 12). One electrical connector (located at rear of
coil) is used for all three coils.
Fig. 11 Ignition Coil AssemblyÐ4.0L 6±Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
Fig. 12 Coil LocationÐ4.0L Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
WJIGNITION CONTROL 8I - 9
CAMSHAFT POSITION SENSOR (Continued)

OPERATION
Although cylinder firing order is the same as 4.0L
Jeep engines of previous years, spark plug firing is
not. The 3 coils dual-fire the spark plugs on cylinders
1-6, 2-5 and/or 3-4. When one cylinder is being fired
(on compression stroke), the spark to the opposite
cylinder is being wasted (on exhaust stroke).
Battery voltage is supplied to the three ignition
coils from the ASD relay. The Powertrain Control
Module (PCM) opens and closes the ignition coil
ground circuit for ignition coil operation.
Base ignition timing is not adjustable.By con-
trolling the coil ground circuit, the PCM is able to set
the base timing and adjust the ignition timing
advance. This is done to meet changing engine oper-
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
Because of coil design, spark plug cables (second-
ary cables) are not used. The cables are integral
within the coil rail.
REMOVAL
A one-piece coil rail assembly containing three
individual coils is used on the 4.0L engine (Fig. 13).
The coil rail must be replaced as one assembly. The
bottom of the coil is equipped with 6 individual rub-
ber boots (Fig. 13) to seal the 6 spark plugs to the
coil. Inside each rubber boot is a spring. The spring
is used for an electrical contact between the coil and
the top of the spark plug. These rubber boots and
springs are a permanent part of the coil and are not
serviced separately.
(1) Disconnect negative battery cable at battery.
(2) The coil is bolted directly to the cylinder head.
Remove 4 coil mounting bolts (Fig. 14).
(3) Carefully pry up coil assembly from spark
plugs. Do this by prying alternately at each end of
coil until rubber boots have disengaged from all
spark plugs. If boots will not release from spark
plugs, use a commercially available spark plug boot
removal tool. Twist and loosen a few boots from a few
spark plugs to help remove coil.
(4) After coil has cleared spark plugs, position coil
for access to primary electrical connector. Disconnect
connector from coil by pushing slide tab outwards to
right side of vehicle (Fig. 15). After slide tab has been
positioned outwards, push in on secondary release
lock (Fig. 15) on side of connector and pull connector
from coil.
(5) Remove coil from vehicle.
Fig. 13 Ignition Coil AssemblyÐ4.0L 6±Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
Fig. 14 Ignition Coil Rail LocationÐ4.0L 6±Cylinder
Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
8I - 10 IGNITION CONTROLWJ
COIL RAIL (Continued)