2002 JEEP GRAND CHEROKEE duct

FLOOR CONSOLE
REMOVAL
CAUTION: The ACM should be depowered by dis-
connecting the negative battery cable in any opera-
tion requiring the key to be turned ªONº, while
working in the console area. E.G. console, carpet,
or seat removal or installation; shifter linkage
adjustment or replacement; parking brake cable
replacement or adjustment. Failure to take proper
precautions could result in accidental airbag
deployment and possible personal injury.
(1) Set park brake.
(2) Place transmission shift lever and transfer case
lever in full rearward position.
(3) Remove mat from front bin and remove screws
attaching front of console to floor (Fig. 8).
(4) Remove screws attaching rear bin to console.
(5) Remove rear bin.
(6) Pull rear passenger cupholder outward to
access screws.
(7)
Remove screws attaching rear of console to floor.
(8) Lift the console upward and rearward.
(9) Remove console from vehicle.
INSTALLATION
CAUTION: The ACM should be depowered by dis-
connecting the negative battery cable in any opera-
tion requiring the key to be turned ªONº, while
working in the console area. E.G. console, carpet,
or seat removal or installation; shifter linkage
adjustment or replacement; parking brake cable
replacement or adjustment. Failure to take proper
precautions could result in accidental airbag
deployment and possible personal injury.
(1) Position console in vehicle. Ensure rear passen-
ger HEVAC duct is engaged.
(2) Install screws attaching rear of console to floor.
(3) Position rear bin in console.
(4) Install screws attaching rear bin to console.
(5) Install screws attaching front of console to floor
and place front bin mat in front bin.
(6) Return transmission shift lever and transfer
case lever to original position.
(7) Release park brake.
Fig. 8 Floor Console
1 - REAR BIN
2 - CONSOLE LID
3 - SHIFTER CONSOLE
4 - BRACKET5 - PARKING BRAKE
6 - FRONT PIN
7-MAT
23 - 76 INTERIORWJ

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES..........81
PAINT CODE
DESCRIPTION.........................81
BASE COAT/CLEAR COAT FINISH
DESCRIPTION.........................81PAINT TOUCH-UP
DESCRIPTION.........................82
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION.........................82
PAINT
SPECIFICATIONS - PAINT CODES
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Dark Garnet Red
PearlcoatXRV
Inferno Red Tinted
PearlcoatWEL
Woodland Brown Satin
GlowYUB
Onyx Green Pearlcoat YJR
Steel Blue Pearlcoat XBQ
Patriot Blue Pearlcoat WBT
Silverstone Metallic
ClearcoatXS5
Graphite Metallic
ClearcoatZDR
Black Clearcoat DX8
Stone White Clearcoat SW1
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Dark Slate Grey DV
Taupe L5
Sandstone T5
Dark Slate/Light Slate DB
LAREDO FASCIA/CLADDING COLORS
COLOR DAIMLERCHRYSLER
CODE
Dark Grey Metallic XS9
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. The plate is located on the in the
engine compartment and attached to the top of the
right frame rail. Refer to the Introduction section at
the front of this manual for body code plate descrip-
tion. The paint code is also identified on the Vehicle
Safety Certification Label which is located on the
drivers door shut face. The first digit of the paint
code listed on the vehicle indicates the sequence of
application, i.e.: P = primary coat, Q = secondary
coat.
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
The original equipment finish is a multi-step pro-
cess that involves cleaning, electrodeposition (e-coat),
base coat, and clear coat steps. Additionally, selected
areas of the vehicle may be coated with an anti-chip
finish.
WJPAINT 23 - 81

PAINT TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat. Refer to Introduction group of this manual for
Body Code Plate information.
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
OPERATION
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clear coat, apply clear top coat
to touch-up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
CAUTION: Do not remove more than .5 mils of
clearcoat finish, if equipped. Base coat paint must
retain clear coat for durability.
Use a Paint Thickness Gauge #PR-ETG-2X or equiv-
alent to determine film thickness before and after
the repair.
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
23 - 82 PAINTWJ

VACUUM RESERVOIR
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................35
INSTALLATION.........................35EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................35
INSTALLATION.........................35
CONTROLS
DIAGNOSIS AND TESTING - VACUUM SYSTEM
Vacuum control is used to operate the mode doors
in the standard equipment manual temperature con-
trol system HVAC housing. Testing of the A/C Heater
mode control switch operation will determine if the
vacuum and electrical controls are functioning. How-
ever, it is possible that a vacuum control system that
operates perfectly at engine idle (high engine vac-
uum) may not function properly at high engine
speeds or loads (low engine vacuum). This can be
caused by leaks in the vacuum system, or a faulty
vacuum check valve.
A vacuum system test will help to identify the
source of poor vacuum system performance or vac-
uum system leaks. Before starting this test, stop the
engine and make certain that the problem isn't a dis-
connected vacuum supply tube at the engine intake
manifold vacuum tap or the vacuum reservoir.
Use an adjustable vacuum test set (Special Tool
C-3707-B) and a suitable vacuum pump to test the
HVAC vacuum control system. With a finger placed
over the end of the vacuum test hose probe (Fig. 1),
adjust the bleed valve on the test set gauge to obtain
a vacuum of exactly 27 kPa (8 in. Hg.). Release and
block the end of the probe several times to verify that
the vacuum reading returns to the exact 27 kPa (8
in. Hg.) setting. Otherwise, a false reading will be
obtained during testing.
VACUUM CHECK VALVES
(1) Remove the vacuum check valve to be tested.
The valves are located in the (black) vacuum supply
tubes at either the engine intake manifold vacuum
tap, or on the bottom of the HVAC unit behind the
passenger front floor duct.
(2) Connect the test set vacuum supply hose to the
A/C Heater control side of the valve. When connected
to this side of the check valve, no vacuum should
pass and the test set gauge should return to the 27
kPa (8 in. Hg.) setting. If OK, go to Step 3. If not OK,
replace the faulty valve.
(3) Connect the test set vacuum supply hose to the
engine vacuum side of the valve. When connected to
this side of the check valve, vacuum should flow
through the valve without restriction. If not OK,
replace the faulty valve.
A/C HEATER CONTROL
(1) Connect the test set vacuum probe to the
HVAC vacuum supply (black) tube in the engine com-
partment. Position the test set gauge so that it can
be viewed from the passenger compartment.
(2) Place the A/C Heater mode control switch knob
in each mode position, one position at a time, and
pause after each selection. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each selection is made. If not OK, a component or
vacuum line in the vacuum circuit of the selected
mode has a leak. See the procedure in Locating Vac-
uum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
Fig. 1 ADJUST VACUUM TEST BLEED VALVE -
TYPICAL
1 - VACUUM PUMP TOOL C-4289
2 - VACUUM TEST SET C-3707
3 - BLEED VALVE
4 - PROBE
24 - 10 CONTROLSWJ

INSTALLATION
INSTALLATION - RECIRCULATION DOOR
VACUUM ACTUATOR
(1) Install the recirculation door vacuum actuator
on the HVAC housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Engage the recirculation door actuating rod
with the recirculation door lever.
(3) Engage the recirculation door pivot connection
with the door pivot pin.
(4) Plug in the vacuum harness connector to the
recirculation door vacuum actuator.
(5) Install the instrument panel in the vehicle.
Refer to Instrument Panel System for the procedures.
INSTALLATION - RECIRCULATION DOOR
ELECTRIC ACTUATOR
(1) Install the recirculation door actuator on the
recirculation door housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Install the recirculation door housing on the
HVAC unit and tighten the mounting screws to 2.2
N´m (20 in. lbs.).
(3) Plug in the wire harness connector to the recir-
culation door actuator.
(4) Install the instrument panel in the vehicle.
Refer to Instrument Panel System for the procedures.
VACUUM CHECK VALVE
DESCRIPTION
Two vacuum check valves (non AZC only) are
installed on the vacuum supply system. One is on the
accessory vacuum supply line in the engine compart-
ment, near the vacuum tap on the engine intake
manifold. A second vacuum check valve is located on
the bottom of the HVAC unit behind the passenger
front floor duct on the black vacuum line. The vac-
uum check valves are designed to allow vacuum to
flow in only one direction through the accessory vac-
uum supply circuits.
OPERATION
The use of a vacuum check valve helps to maintain
the system vacuum needed to retain the selected A/C
Heater mode settings. The check valve will prevent
the engine from bleeding down system vacuum
through the intake manifold during extended heavy
engine load (low engine vacuum) operation.
The vacuum check valve cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
(1) Unplug the HVAC vacuum supply line connec-
tor at the vacuum check valve near the engine intake
manifold vacuum adapter fitting.
(2) Note the orientation of the check valve in the
vacuum supply line for correct installation.
(3) Unplug the vacuum check valve from the vac-
uum supply line fittings.
INSTALLATION
(1) Plug in the vacuum check valve at the vacuum
supply line fittings, noting the orientation of the
check valve in the vacuum supply line for correct
installation.
(2) Plug in the HVAC vacuum supply line connec-
tor at the vacuum check valve near the engine intake
manifold vacuum adapter fitting.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is mounted in the right front
of the vehicle behind the headlamp mounting module
(Fig. 22). The headlamp mounting module and head-
lamp assembly must be removed from the vehicle to
access the vacuum reservoir for service. Refer to
Lamps/Lighting for the procedures.
OPERATION
Engine vacuum is stored in the vacuum reservoir.
The stored vacuum is used to operate the vacuum-
Fig. 21 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
24 - 34 CONTROLSWJ
RECIRCULATION DOOR ACTUATOR (Continued)

DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
REMOVAL.............................36
INSTALLATION.........................36
BLOWER MOTOR
DESCRIPTION.........................37
OPERATION...........................37
DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................37
REMOVAL.............................37
INSTALLATION.........................38
DEFROSTER DUCTS
REMOVAL.............................38
INSTALLATION.........................39
FLOOR DISTRIBUTION DUCTS
REMOVAL.............................39
INSTALLATION.........................39
INSTRUMENT PANEL DUCTS
REMOVAL.............................39
INSTALLATION.........................39
REAR FLOOR HEAT DUCT
REMOVAL.............................39INSTALLATION.........................39
HVAC HOUSING
REMOVAL.............................41
DISASSEMBLY.........................42
ASSEMBLY............................45
INSTALLATION.........................45
BLEND DOOR
REMOVAL.............................46
INSTALLATION.........................46
MODE DOOR
REMOVAL
REMOVAL - PANEL OUTLET DOOR.......46
REMOVAL - HEAT/DEFROST DOOR.......47
REMOVAL - PANEL/DEFROST DOOR......48
INSTALLATION
INSTALLATION - PANEL OUTLET DOOR....49
INSTALLATION - HEAT/DEFROST DOOR . . . 49
INSTALLATION - PANEL/DEFROST DOOR . . 49
RECIRCULATION DOOR
REMOVAL.............................49
INSTALLATION.........................50
AIR OUTLETS
REMOVAL
The driver side, and passenger side panel outlets
are available for service. The center outlets are only
serviced as part of the instrument cluster center
bezel unit.
(1) Remove the instrument panel top pad from the
instrument panel. Refer to Instrument Panel System
for the procedures.
(2) Remove the two screws that secure each outlet
to the backside of the instrument panel top pad (Fig.
1).
(3) Remove the outlet from the top pad.
INSTALLATION
(1) Fasten the outlet to the top pad. Tighten the
mounting screws to 2.2 N´m (20 in. lbs.).
(2) Install the instrument panel top pad on the
instrument panel. Refer to Instrument Panel System
for the procedures.
Fig. 1 PANEL OUTLETS (PASSENGER SIDE)
1 - MOUNTING SCREWS
2 - MOUNTING SCREWS
3 - PANEL OUTLETS
24 - 36 DISTRIBUTIONWJ

(1) Disconnect and isolate the battery negative
cable.
(2) Pinch the connector retainer and unplug the
blower motor wire harness from the blower motor
(Fig. 2).
(3) Remove the three screws that secure the
blower motor and blower wheel assembly to the
HVAC housing, using either a T-25 Torxthead or
flat-bladed screwdriver.
(4) Lower the blower motor and wheel from the
HVAC housing.
(5) Remove the blower wheel retainer clip (Fig. 3).
(6) Remove the wheel from the blower motor shaft.
INSTALLATION
(1) Press the blower wheel hub onto the blower
motor shaft. Be sure the flat on the blower motor
shaft is indexed to the flat on the inside of the blower
wheel hub.
(2) Install the retainer clip over the blower wheel
hub.
(3) Install the blower motor in the HVAC housing
with three mounting screws. Tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(4) Plug the blower motor wire harness connector
into the blower motor socket.
(5) Connect the battery negative cable.
DEFROSTER DUCTS
REMOVAL
(1) Remove the instrument panel assembly from
the vehicle(Refer to 23 - BODY/INSTRUMENT
PANEL - REMOVAL).
(2) Remove the three screws that secure the
defroster duct to the HVAC unit housing (Fig. 4).
(3) Remove the defroster duct from the HVAC unit
housing.
Fig. 2 BLOWER MOTOR (HOUSING REMOVED
FROM VEHICLE)
1 - BLOWER MOTOR RESISTOR
2 - BLOWER MOTOR
3 - GROUND STRAP
4 - ELECTRICAL CONNECTORS
5 - HEATER CORE TUBES
Fig. 3 BLOWER MOTOR WHEEL REMOVE/INSTALL
1 - BLOWER MOTOR WHEEL
2 - RETAINER CLIP
Fig. 4 HVAC DEFROSTER DUCT
1 - HVAC UNIT HOUSING
2 - INSTRUMENT PANEL
3 - SCREWS
4 - DEFROSTER DUCT
24 - 38 DISTRIBUTIONWJ
BLOWER MOTOR (Continued)

INSTALLATION
(1) Install the defroster duct on the HVAC unit
housing.
(2) Install the three screws that secure the
defroster duct to the HVAC unit housing. Tighten the
mounting screws to 2.2 N´m (20 in. lbs.).
(3) Install the instrument panel assembly in the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL -
INSTALLATION).
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) To remove the driver side floor duct from the
vehicle, remove the knee blocker panel for access to
attaching screw. See Instrument Panel System for
the procedures.
(2) The passenger side floor duct fastener can be
accessed under the right-center instrument panel.
(3) Remove the screw that secures the floor duct(s)
to the HVAC housing (Fig. 5).
INSTALLATION
(1) Attach the floor duct(s) to the HVAC housing.
(2) Install the screw that secures the floor duct(s)
to the HVAC housing. Tighten the mounting screws
to 2.2 N´m (20 in. lbs.).
(3) Install the knee blocker panel. See Instrument
Panel System for the procedures.
INSTRUMENT PANEL DUCTS
REMOVAL
(1) Remove the instrument panel top pad from the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL TOP COVER - REMOVAL).
(2) Unsnap the duct extension(s) from the instru-
ment panel structural duct assembly (Fig. 6).
(3) Remove the duct extension(s) from the instru-
ment panel (Fig. 7).
INSTALLATION
(1) Connect the duct extension(s) to the instru-
ment panel.
(2) Snap the duct extension(s) to the instrument
panel structural duct assembly.
(3) Install the instrument panel top pad in the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL TOP COVER - INSTALLA-
TION).
REAR FLOOR HEAT DUCT
REMOVAL
(1) To remove the rear floor ducts from the vehicle,
remove the knee blocker panels for access, and pull
carpeting back.
(2) Pull the floor ducts from the HVAC housing
(Fig. 8).
NOTE: The ductwork running from the HVAC hous-
ing rearward through the passenger compartment is
molded into the carpeting, and must be replaced as
a unit if damaged.
INSTALLATION
(1) Attach the floor ducts to the HVAC housing.
(2) Install the knee blocker panels.
(3) Install the carpeting back in its original posi-
tion.
Fig. 5 FLOOR DUCTS (HOUSING REMOVED)
1 - FLOOR DUCT ADAPTER
2 - HEAT/DEFROST DOOR SUB-ASSEMBLY
3 - DOOR LEVERS
4 - LOWER HOUSING
5 - FLOOR DUCTS
6 - LINKAGE
7 - RETAINING TABS
WJDISTRIBUTION 24 - 39
DEFROSTER DUCTS (Continued)