2002 JEEP GRAND CHEROKEE Lamps

NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.
(2) Position the catalytic converter onto the
exhaust pipe flange connection. Tighten retaining
nuts to 28 N´m (250 in. lbs.) (Fig. 12).
(3) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
N´m (35 ft. lbs.) torque (Fig. 9).
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
(6) After initial start-up, check the engine exhaust
manifold to exhaust pipe nuts for proper torque.
Fig. 10 Catalytic ConverterÐRemoval
1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER
Fig. 11 Exhaust Pipe 4.0L
1 - NUT
2 - EXHAUST MANIFOLD
3 - TRANSMISSION SUPPORT
4 - EXHAUST PIPE
5 - MINI CATALYTIC CONVERTER
6 - BOLT
Fig. 12 Installing Exhaust Clamps
1 - CATALYTIC CONVERTER
2 - MUFFLER
WJEXHAUST SYSTEM 11 - 9
EXHAUST PIPE - 4.0L (Continued)

EXHAUST PIPE - 4.7L
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
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.
(1) Raise and support the vehicle.(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 13).
(4) Remove the retaining nuts holding catalytic
converter to exhaust pipe (Fig. 14).
(5) Disconnect the exhaust pipe from the exhaust
manifold. (Fig. 15)
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the exhaust pipe to the engine exhaust
manifold. Tighten the nuts (A) to 31 N´m (23 ft. lbs.)
(Fig. 15).
Fig. 13 4.7L Catalytic Converter and O2 Sensor Configuration - 50 State Emissions
11 - 10 EXHAUST SYSTEMWJ

NOTE: When servicing the exhaust system, replace
the factory installed uni-clamp with standard u-bolt
clamps.
(2) Position the catalytic converter onto the
exhaust pipe flange connection. Tighten retaining
nuts to 28 N´m (250 in. lbs.). (Fig. 16)
(3) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
N´m (35 ft. lbs.) torque (Fig. 13).
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
(6) After initial start-up, check the engine exhaust
manifold to exhaust pipe nuts for proper torque.
Fig. 14 Catalytic ConverterÐRemoval
1 - EXHAUST PIPE WITH FLANGE
2 - NUTS (3)
3 - CATALYTIC CONVERTER
Fig. 15 Exhaust Pipe 4.7L
1 - EXHAUST PIPE HANGER
A - NUTS (4)
3 - EXHAUST PIPE
B - BOLTS (4)
Fig. 16 Installing Exhaust Clamps
1 - CATALYTIC CONVERTER
2 - MUFFLER
WJEXHAUST SYSTEM 11 - 11
EXHAUST PIPE - 4.7L (Continued)

TAILPIPE
DESCRIPTION
The tailpipe is also made of stainless steel. (Fig.
18) .
OPERATION
The Tailpipe channels the exhaust out of the muf-
fler and out from under the vehicle to control noise
and prevent exhaust gas fumes from entering the
passenger compartment
Fig. 19 Installing Exhaust Clamps
1 - CATALYTIC CONVERTER
2 - MUFFLER
Fig. 20 Muffler and Tailpipe
1 - CATALYTIC CONVERTER
2 - TAILPIPE HANGER
3 - TAILPIPE
4 - MUFFLER
WJEXHAUST SYSTEM 11 - 13
MUFFLER (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)

(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove electrical wire connector at sending
unit terminals.
(4) Press upward on release tab (Fig. 7) to remove
sending unit from pump module.
INSTALLATION
The fuel gauge sending unit (fuel level sensor) and
float assembly is located on the side of fuel pump
module (Fig. 6). The fuel pump module is located
within the fuel tank.
(1) Position sending unit to pump module and
snap into place.
(2) Connect electrical connector to terminals.
(3) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(4) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL LINES
DESCRIPTION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
Fig. 6 Fuel Gauge Sending Unit Location
1 - FUEL PUMP MODULE
2 - FUEL GAUGE FLOAT
3 - ELECTRIC FUEL PUMP
4 - INLET FILTER
5 - FUEL GAUGE SENDING UNIT
6 - PIGTAIL HARNESS
Fig. 7 Fuel Gauge Sending Unit Release Tab
1 - ELECTRICAL CONNECTOR
2 - FUEL GAUGE SENDING UNIT
3 - RELEASE TAB
4 - FUEL PUMP MODULE
14 - 8 FUEL DELIVERYWJ
FUEL LEVEL SENDING UNIT / SENSOR (Continued)

CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tube (Fig. 22). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body air box.
(5) Remove air box at throttle body.
(6) Remove wiring at rear of generator.
(7) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(8) Remove vacuum lines at throttle body.(9) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 23). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(10) Disconnect electrical connectors at throttle
body.
(11) Disconnect electrical connectors at MAP and
IAT sensors.
Fig. 21 Fuel Injector Rail/Fuel DamperÐ4.0L Engine
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
10 - MOUNTING BOLTS (4)
11 - QUICK-CONNECT FITTING
Fig. 22 FUEL INJECTOR RAIL - 4.7L V-8 EN
1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
14 - 16 FUEL DELIVERYWJ
FUEL RAIL (Continued)

(19) Disconnect fuel return line at fuel filter/fuel
pressure regulator (Fig. 36). Refer to Quick-Connect
Fittings for procedures.
(20) Disconnect fuel pressure line at fuel filter/fuel
pressure regulator (Fig. 36). Refer to Quick-Connect
Fittings for procedures.
(21) Disconnect EVAP canister vent line near front
of tank (Fig. 36).
(22) Disconnect fuel pump module electrical con-
nector (pigtail harness) near front of tank (Fig. 36).
Harness connector is clipped to body.
(23) Remove left / front tank support bracket bolt
at frame (Fig. 37).
(24)WITHOUT TRAILER HITCH:Remove tank-
to-frame mounting bolts (Fig. 39). Remove rear tank
support bracket bolts at frame (Fig. 38). Carefully
lower tank until clear of vehicle. Place tank on floor.
(25)WITH TRAILER HITCH:Remove tank /
hitch mounting bolts (Fig. 40). Carefully lower tank
until clear of vehicle. Place tank on floor.
(26) If necessary, separate skid plate from fuel
tank by removing 2 fuel tank strap nuts (Fig. 39) and
remove 2 tank straps.
(27) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation.
(28) If hoses are to be removed at fuel tank end,
note painted alignment (indexing) markings on
hoses, and molded indexing tangs on tank before
removal. Remove hoses.
(29) If necessary, remove 3 fuel filler tube assem-
bly mounting bolts (Fig. 41) and remove fuel filler
tube.
INSTALLATION
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(1) If necessary, position fuel filler tube assembly
to body. Install 3 bolts and tighten to 2 N´m (15 in.
lbs.) torque.
(2) If necessary, connect quick-connect fittings to
fuel pump module.
(3) If fuel pump module is being installed, refer to
Fuel Pump Module Removal/Installation.
(4) Install fuel fill/vent hoses to tank fittings. To
prevent hoses from kinking, rotate each hose until
painted indexing mark on hose is aligned to molded
indexing tang on tank.
(5) Install hose clamps to hoses. Refer to Torque
Specifications.(6) If necessary, position fuel tank into skid plate.
Install 2 tank straps and 2 strap nuts (Fig. 39). Refer
to Torque Specifications.
(7) Position fuel tank / skid plate assembly to
hydraulic jack.
(8) Raise tank into position to frame.
(9)WITH TRAILER HITCH:Position trailer
hitch and tow hooks (Fig. 40) to bottom of fuel tank.
Install bolts and nuts loosely.
(10)WITHOUT TRAILER HITCH:Install 2 rear
tank support brackets and bolts (Fig. 38). Install
tank-to-frame bolts. Do not tighten bolts / nuts at
this time.
(11) Install 1 left / front tank support bracket and
bolts / nuts (Fig. 37). Do not tighten bolts / nuts at
this time.
(12) Be sure fuel tank is properly aligned to frame
and body. Tighten all tank, tow hook and trailer
hitch bolts / nuts except for 3 support brackets.
Tighten all 3 (2 rear and 1 left / front) support
bracket bolts / nuts last. Refer to Torque Specifica-
tions.
(13)
(14) Connect fuel pump module pigtail harness
electrical connector near front of tank.
(15) Connect both fuel lines to fuel filter/fuel pres-
sure regulator. Refer to Quick-Connect Fittings for
procedures.
(16) Connect EVAP hose near front of tank.
(17) Position rear axle vent hose and install new
tie strap (Fig. 32).
(18) Install heat shield nuts / bolts (Fig. 35). Refer
to Torque Specifications.
(19) Connect ORVR hose elbow (Fig. 33) to top of
EVAP canister.
(20) Connect fuel vent hose to fuel vent tube (Fig.
32).
(21) Install fuel fill hose and clamp to fuel fill tube
(Fig. 32).
(22) Install 3 LDP mounting bolts (Fig. 29).
(23) While raising support bracket, connect LDP
wiring clip (Fig. 31). Install front section of two-piece
support bracket to rear section with 3 attaching bolts
located on bottom of support bracket (Fig. 30).
(24) Install support bracket brace bolt (Fig. 30).
(25) Tighten 2 support bracket nuts at frame rail
(Fig. 29).
(26) Install fuel tank-to-rear bumper fascia clips
(Fig. 34).
(27) Using new plastic rivets, install stone shield
behind left/rear wheel (Fig. 28).
(28) Install left rear wheel/tire.
(29) Lower vehicle and connect negative battery
cable to battery.
(30) Fill tank with fuel and check for leaks.
14 - 20 FUEL DELIVERYWJ
FUEL TANK (Continued)