2002 JEEP GRAND CHEROKEE Drive shaft

(5) Push sensor against flywheel/drive plate. With
sensor pushed against flywheel/drive plate, tighten
mounting bolt to 7 N´m (60 in. lbs.) torque.
(6) Route sensor wiring harness into wire shield.
(7) Connect sensor pigtail harness electrical con-
nector to main wiring harness.
INSTALLATION - 4.7L
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block 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
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Install starter motor. Refer to Starter Removal/
Installation.
FUEL INJECTOR
DESCRIPTION
A separate fuel injector (Fig. 24) is used for each
individual cylinder.
OPERATION
OPERATION
The fuel injectors are electrical solenoids. The
injector contains a pintle that closes off an orifice at
the nozzle end. When electric current is supplied to
the injector, the armature and needle move a short
distance against a spring, allowing fuel to flow out
the orifice. Because the fuel is under high pressure, a
fine spray is developed in the shape of a pencil
stream. The spraying action atomizes the fuel, add-
ing it to the air entering the combustion chamber.
The top (fuel entry) end of the injector (Fig. 24) is
attached into an opening on the fuel rail.
The nozzle (outlet) ends of the injectors are posi-
tioned into openings in the intake manifold just
above the intake valve ports of the cylinder head.
The engine wiring harness connector for each fuel
injector is equipped with an attached numerical tag
(INJ 1, INJ 2 etc.). This is used to identify each fuel
injector.
The injectors are electrically energized, individu-
ally and in a sequential order by the Powertrain Con-
trol Module (PCM). The PCM will adjust injector
pulse width by switching the ground path to each
individual injector on and off. Injector pulse width is
the period of time that the injector is energized. The
PCM will adjust injector pulse width based on vari-
ous inputs it receives.
Battery voltage is supplied to the injectors through
the ASD relay.
The PCM determines injector pulse width based on
various inputs.
OPERATION - PCM OUTPUT
The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the intake
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.).
This is used to identify each fuel injector with its
respective cylinder number.
The injectors are energized individually in a
sequential order by the Powertrain Control Module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage (12 volts +) is supplied to the injec-
tors through the ASD relay. The ASD relay will shut-
down the 12 volt power source to the fuel injectors if
the PCM senses the ignition is on, but the engine is
not running. This occurs after the engine has not
been running for approximately 1.8 seconds.
Fig. 24 Fuel InjectorÐ4.0L/4.7L Engines
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
WJFUEL INJECTION 14 - 43
CRANKSHAFT POSITION SENSOR (Continued)

(13) Remove the column coupler bolt (Fig. 13) and
slide the coupler off the column shaft.
(14) Remove the column mounting nuts (Fig. 13)
and lower column off mounting studs. Remove the
column from the vehicle.
(15) Remove the ignition switch, cylinder and
SKIM, (Refer to 19 - STEERING/COLUMN/LOCK
CYLINDER HOUSING - REMOVAL). (Fig. 14).INSTALLATION
WARNING: BEFORE SERVICING THE STEERING COL-
UMN THE AIRBAG SYSTEM MUST BE DISARMED.
FAILURE TO DO SO MAY RESULT IN ACCIDENTAL
DEPLOYMENT OF THE AIRBAG AND POSSIBLE PER-
SONAL INJURY. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - INSTALLATION).
(1) Install the ignition switch, cylinder and SKIM-
,(Refer to 19 - STEERING/COLUMN/IGNITION
SWITCH - INSTALLATION).
(2) Install the column into the vehicle and lift the
column up onto the mounting studs. Install the
mounting nuts and tighten to 12 N´m (105 in. lbs.).
(3) Slid the coupler onto the column shaft and
install the coupler bolt. Tighten the coupler bolt to 49
N´m (36 ft. lbs.).
(4) Turn the ignition key to the on position then
release and install the shifter interlock cable (Fig.
12) into ignition lock cylinder housing.
(5) Verify ignition switch and shifter interlock
operation.,(Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 42RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
(6) Slide the multifuction switch and clock spring
onto the column as an assembly (Fig. 11).
(7) Install the multifuction switch mounting screw
(Fig. 10).
(8) Connect the multifuction switch (Fig. 9) and
ignition switch harness.
(9) Install the upper fixed shroud and mounting
screws (Fig. 8).
(10) Install the lower steering column shroud to
the steering column. Install and tighten the mount-
ing screw.
(11) Install the upper column shroud. Align the
upper shroud to the lower shroud and snap the two
shroud halves together.
(12) Install the knee blocker cover (Fig. 5),(Refer
to 23 - BODY/INSTRUMENT PANEL - INSTALLA-
TION).
(13) Install the cluster bezel by inserting it into
the instrument panel (Fig. 4).
(14) Align the steering wheel with the column
index spline and install the wheel on the column
shaft. Pull the clockspring wire harness through the
steering wheel armature spokes.
(15) Install and tighten the steering wheel mount-
ing nut to 61 N´m (45 ft. lbs.).
(16) Connect the steering wheel wire harness con-
nector to the clock spring connector.
(17) Install the airbag,(Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(18) Connect the negative (ground) cable to the
battery.
Fig. 13 Column Coupler Bolt And Mounting Nuts
1 - COLUMN MOUNTING NUTS
2 - COUPLER BOLT
Fig. 14 Ignition Switch And SKIM
1 - SKIM
2 - IGNITION SWITCH
WJCOLUMN 19 - 11
COLUMN (Continued)

PITMAN SHAFT
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing.
(9) Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig.
7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
Fig. 5 Center Stub
1 - WRENCH
2 - STUB SHAFT
Fig. 6 Cover and Pitman Shaft
1 - ADJUSTER NUT
2 - PITMAN SHAFT COVER
3 - O-RING
4 - GEAR HOUSING
5 - PITMAN SHAFT
Fig. 7 Oil Seal Removal
1 - PULLER
2 - STEERING GEAR
19 - 20 GEARWJ

(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
Fig. 8 Oil Seal Retaining Ring
1 - SNAP RING PLIERS
2 - RETAINING RING
Fig. 9 Bearing Driver
1 - UPPER BEARING
2 - LOWER BEARING
3 - DRIVER
Fig. 10 Upper Pitman Shaft Bearing
1 - DRIVER
2 - UPPER BEARING
Fig. 11 Lower Pitman Shaft Bearing
1 - STEERING GEAR
2 - BEARING SHOULDER
3 - DRIVER
4 - LOWER BEARING
WJGEAR 19 - 21
PITMAN SHAFT (Continued)

PITMAN SHAFT BEARING
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing (Fig. 12).
(9)
Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig. 7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
PITMAN SHAFT SEAL
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing (Fig. 12).
Fig. 12 Backup Washers
1 - METAL BACK UP WASHER
2 - PLASTIC BACK UP WASHER
19 - 22 GEARWJ

(9) Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig.
7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
RACK PISTON/VALVE
ASSEMBLY
REMOVAL
(1) Remove the steering gear (Refer to 19 -
STEERING/GEAR - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(5) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(6) Remove the pitman shaft cover o-ring.
(7) Remove stub shaft housing bolts (Fig. 13).
(8) Remove the housing from the stub shaft (Fig.
14).
Fig. 13 Stub Shaft Housing
1 - STUB SHAFT HOUSING
2 - BOLTS
3 - STUB SHAFT
Fig. 14 Housing Removal
1 - STEERING GEAR
2 - STUB SHAFT HOUSING
WJGEAR 19 - 23
PITMAN SHAFT SEAL (Continued)

PUMP
DESCRIPTION - 4.0L, 4.7L
Hydraulic pressure for the power steering system
is provided by a belt driven power steering pump
(Fig. 1) and (Fig. 2). The pump shaft has a
pressed-on drive pulley that is belt driven by the
crankshaft pulley.
OPERATION
OPERATION - 4.7L
The power steering pump is a constant flow rate
and displacement, vane-type pump. The pump has
internal parts that operate submerged in fluid. The
flow control orifice and the pressure relief valve,
which limits the pump pressure, are internal to the
pump. The reservoir is attached to the pump body
with spring clips. The power steering pump is used
to drive the hydraulic engine cooling fan, which sep-
arates the flow to the fan gerotors and the power
steering gear. The power steering pump is connected
to the engine cooling fan by pressure and return
hoses and the pump is connected to the steering gear
via a return hose from the steering cooler (Fig. 2).NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.OPERATION - 4.0L
The power steering pump is a constant flow rate
and displacement, vane-type pump. The pump inter-
nal parts operate submerged in fluid. The flow con-
trol orifice is part of the high pressure line fitting.
The pressure relief valve inside the flow control valve
limits the pump pressure. The reservoir is attached
to the pump body with spring clips. The power steer-
ing pump is connected to the steering gear by the
pressure and return hoses (Fig. 1).
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
Fig. 1 Pump With Integral Reservoir
1 - CAP
2 - FLUID RESERVOIR (TYPICAL)
3 - HIGH-PRESSURE FITTING
4 - DRIVE PULLEY
5 - PUMP BODY
6 - RESERVOIR CLIP
Fig. 2 4.7L POWER STEERING PUMP
1 - PRESSURE HOSE QUICK CONNECT NUT
2 - CAP
3 - FLUID RESERVOIR
4 - LOW-PRESSURE RETURN FROM THE COOLER
5 - LOW-PRESSURE RETURN FROM THE HYDRAULIC FAN
DRIVE
6 - PUMP BODY
7 - HIGH PRESSURE FITTING
19 - 32 PUMPWJ

INSTALLATION
NOTE: The pulley is marked front for installation.
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Replace pulley if bent, cracked, or loose.
(2) Install pulley on pump with Installer C-4063-B
or equivalent installer (Fig. 15). The front edge of the
pulley hub must be flush with the end of the shaft.
Ensure the tool and pulley are aligned with the
pump shaft.(3) Install pump assembly.
(4) With Serpentine Belt, run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.).Be
careful that pulley does not contact mounting
bolts.
RESERVOIR
REMOVAL
(1) Remove power steering pump.
(2) Clean exterior of pump.
(3) Clamp the pump body in a soft jaw vice.
NOTE: Use new retaining clips for installation.
(4) Pry up tab and slide the retaining clips off (Fig.
16).
(5) Remove fluid reservoir from pump body.
Remove and discard O-ring seal.
INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent.
(2) Install O-ring seal in housing.
(3) Install reservoir onto housing.
(4) Slide and tap innewreservoir retainer clips
until tab locks to housing.
(5) Install power steering pump.
(6) Add power steering fluid,(Refer to 19 - STEER-
ING/PUMP - STANDARD PROCEDURE).
Fig. 14 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
Fig. 15 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063±B
Fig. 16 Pump Reservoir Clips
1 - RESERVOIR
2 - RETAINING CLIPS
19 - 42 PUMPWJ
PULLEY (Continued)