2002 JEEP GRAND CHEROKEE instrument panel

WELD LOCATIONS
SPECIFICATIONS
WELD LOCATIONS
INDEX
DESCRIPTION FIGURE
RADIATOR SUPPORT BRACKETS 49
FRONT SUSPENSION SUPPORT REINFORCEMENT 50
FRONT LOWER CROSSMEMBER TO COWL SIDE PANEL 51
FRONT SILL TO LOWER CROSSMEMBER 52
FRONT FENDER MOUNTING BRACKET AND REINFORCEMENT 53
FRONT SUSPENSION SUPPORT TO SILLS AND COWL SIDE PANEL 54
LEFT INSTRUMENT PANEL BRACKET TO COWL SIDE PANEL 55
COWL SIDE UPPER REINFORCEMENT TO COWL SIDE AND FRONT SUSPENSION
SUPPORT56
COWL SIDE PANEL TO DASH PANEL AND INNER BODYSIDE PANEL AND SILL 57
PLENUM ASSEMBLY TO COWL SIDE PANEL 58
FRONT LOWER CROSSMEMBER 59
FRONT SUSPENSION SUPPORT TO DASH 60
WIPER MOUNTING BRACKETS TO PLENUM ASSEMBLY 61
COWL TOP AND PLENUM ASSEMBLY 62
LOWER PLENUM REINFORCEMENT TO LOWER PLENUM PANEL 63
DASH PANEL TO LOWER PLENUM PANEL 64
PLENUM ASSEMBLY TO COWL 65
COWL PANEL TO BODYSIDE SILL 66
COWL PANEL TO FRONT FLOOR PAN 67
FRONT SILLS TO DASH AND FRONT FLOOR PAN 68
COWL SIDE PANEL DASH INNER BODYSIDE AND OUTER BODYSIDE PANELS 69
UPPER FRONT INNER PILLAR TO ROOF AND COWL 70
DOOR OPENINGS 71
B-PILLAR REINFORCEMENT TO INNER BODYSIDE APERTURE 72
REAR QUARTER WINDOW TO BODYSIDE APERTURE INNER AND OUTER 73
LOWER REAR QUARTER TO BODYSIDE APERTURE INNER AND OUTER 74
INNER TRACK BAR, LOWER CONTROL ARM AND TRANSMISSION CROSSMEMBER
BRACKETS TO FRONT SILLS75
TRANSMISSION CROSSMEMBER BRACKET AND REINFORCEMENT TO FRONT
SILLS76
UPPER SILLS AND UPPER CONTROL ARM REINFORCEMENT AND BRACKETS TO
FRONT SILLS77
REINFORCEMENT TO FRONT OUTER SILLS 78
FRONT INNER SILL TO FRONT OUTER SILL 79
OUTER TRACK BAR BRACKET TO FRONT OUTER SILL 80
WJBODY STRUCTURE 23 - 153

Fig. 55 LEFT INSTRUMENT PANEL BRACKET TO COWL SIDE PANEL
23 - 160 BODY STRUCTUREWJ
WELD LOCATIONS (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS.......................1
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT........................1
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT........................2DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................2
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE.......................6
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................6
SPECIFICATIONS
A/C APPLICATION TABLE................7
TORQUE SPECIFICATIONS..............8
CONTROLS.............................9
DISTRIBUTION..........................36
PLUMBING.............................51
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the heating-
air conditioning system, the engine cooling system
must be properly maintained. The use of a bug
screen is not recommended. Any obstructions in front
of the radiator or condenser will reduce the perfor-
mance of the air conditioning and engine cooling sys-
tems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Cooling for more infor-
mation before opening, or attempting any service to
the engine cooling system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manual temperature control type heating-air
conditioning system is standard factory-installed
equipment on this model. An electronically controlled
Automatic Zone Control (AZC) type heating-air con-
ditioning system is an available factory-installed
option.
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel.DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service port
coupler sizes are used on the R-134a system to
ensure that the refrigerant system is not accidentally
contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
Fig. 1 Blend-Air HVAC System - (typical)
1 - Blend Door
2 - Expansion Valve
3 - Evaporator Core
4 - Blower Assembly
5 - Recirculation Door
6 - Evaporator Probe
7 - Heater Core
8 - Heat/Defrost Door
9 - Panel/Defrost Door
WJHEATING & AIR CONDITIONING 24 - 1

OPERATION
OPERATION - HEATER AND AIR CONDITIONER
Outside fresh air enters the vehicle through the
cowl top opening at the base of the windshield, and
passes through a plenum chamber to the HVAC sys-
tem blower housing. Air flow velocity can then be
adjusted with the blower motor speed selector switch
on the a/c heater control panel. The air intake open-
ings must be kept free of snow, ice, leaves, and other
obstructions for the HVAC system to receive a suffi-
cient volume of outside air.
It is also important to keep the air intake openings
clear of debris because leaf particles and other debris
that is small enough to pass through the cowl ple-
num screen can accumulate within the HVAC hous-
ing. The closed, warm, damp and dark environment
created within the HVAC housing is ideal for the
growth of certain molds, mildews and other fungi.
Any accumulation of decaying plant matter provides
an additional food source for fungal spores, which
enter the housing with the fresh air. Excess debris,
as well as objectionable odors created by decaying
plant matter and growing fungi can be discharged
into the passenger compartment during HVAC sys-
tem operation.
Both the manual and AZC heater and air condi-
tioner are blend-air type systems. In a blend-air sys-
tem, a blend door controls the amount of
unconditioned air (or cooled air from the evaporator)
that is allowed to flow through, or around, the heater
core. A temperature control knob on the a/c heater
control panel determines the discharge air tempera-
ture by energizing the blend door actuator, which
operates the blend door. This allows an almost imme-
diate control of the output air temperature of the sys-
tem. The AZC system will have separate blend doors
and temperature controls for each front seat occu-
pant.
The mode control knob on the a/c heater control
panel is used to direct the conditioned air to the
selected system outlets. On manual temperature con-
trol systems, the mode control knob switches engine
vacuum to control the mode doors, which are oper-
ated by vacuum actuators. On AZC systems, the
mode control knob switches electrical current to con-
trol the mode doors, which are operated by electronic
actuators.
The outside air intake can be shut off on manual
temperature control systems by selecting the Recircu-
lation Mode with the mode control knob. The outside
air intake can be shut off on Automatic Zone Control
(AZC) type system by pushing the Recirculation
Mode button. This will operate the recirculation door
that closes off the outside fresh air intake and recir-
culates the air that is already inside the vehicle.The air conditioner for all models is designed for
the use of non-CFC, R-134a refrigerant. The air con-
ditioning system has an evaporator to cool and dehu-
midify the incoming air prior to blending it with the
heated air. This air conditioning system uses a ther-
mal expansion valve to meter refrigerant flow to the
evaporator coil. To maintain minimum evaporator
temperature and prevent evaporator freezing, the
system utilizes an evaporator thermister probe with
the appropriate operating logic located in the body
control module (BCM).
OPERATION - REFRIGERANT SYSTEM SERVICE
PORT
The high pressure service port is located on the liq-
uid line near the receiver/drier. The low pressure ser-
vice port is located on the suction line near the
evaporator at the rear of the engine compartment.
Each of the service ports has a threaded plastic
protective cap installed over it from the factory. After
servicing the refrigerant system, always reinstall
both of the service port caps.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE
The air conditioning system is designed to provide
the passenger compartment with low temperature
and low specific humidity air. The evaporator, located
in the HVAC housing on the dash panel below the
instrument panel, is cooled to temperatures near the
freezing point. As warm damp air passes through the
cooled evaporator, the air transfers its heat to the
refrigerant in the evaporator and the moisture in the
air condenses on the evaporator fins. During periods
of high heat and humidity, an air conditioning sys-
tem will be more effective in the Recirculation Mode.
With the system in the Recirculation Mode, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, the air conditioning system performance
levels improve.
Humidity has an important bearing on the tempera-
ture of the air delivered to the interior of the vehicle. It
is important to understand the effect that humidity has
on the performance of the air conditioning system.
When humidity is high, the evaporator has to perform a
double duty. It must lower the air temperature, and it
must lower the temperature of the moisture in the air
that condenses on the evaporator fins. Condensing the
moisture in the air transfers heat energy into the evap-
orator fins and tubing. This reduces the amount of heat
the evaporator can absorb from the air. High humidity
greatly reduces the ability of the evaporator to lower
the temperature of the air.
24 - 2 HEATING & AIR CONDITIONINGWJ
HEATING & AIR CONDITIONING (Continued)

However, evaporator capacity used to reduce the
amount of moisture in the air is not wasted. Wring-
ing some of the moisture out of the air entering the
vehicle adds to the comfort of the passengers.
Although, an owner may expect too much from their
air conditioning system on humid days. A perfor-
mance test is the best way to determine whether the
system is performing up to standard. This test also
provides valuable clues as to the possible cause of
trouble with the air conditioning system.
If the vehicle has the optional Automatic Zone Control
(AZC) system, and has intermittent operational prob-
lems or fault codes, be certain that the wire harness
connectors on the HVAC housing are properly seated
(Fig. 2). To check this condition, unplug the two wire
harness connector halves, then plug them in again.
Before performing the following procedure, (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - CAUTION) (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING). The air
temperature in the test room and in the vehicle must
be a minimum of 21É C (70É F) for this test.
(1)
Connect a tachometer and a manifold gauge set.
(2) If the vehicle has the standard manual temper-
ature control, set the A/C Heater mode control switch
knob in the Panel position, the temperature control
knob in the full cool (Fresh Air Mode) position, the
A/C button in the On position, and the blower motor
switch knob in the highest speed position. If the vehi-
cle has the optional AZC, set the A/C Heater mode
control switch knob in the Panel position, the tem-
perature control knob in the full cool position, the
A/C button in the On position, and the blower motor
switch knob in the highest (manual) speed position.
(3) Start the engine and hold the idle at 1,300 rpm
with the compressor clutch engaged.
(4) The engine should be at operating temperature.
The doors and windows must be open.
(5)
Insert a thermometer in the driver side center
A/C (panel) outlet. Operate the engine for five minutes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity.(7) With the compressor clutch engaged, record the
discharge air temperature and the compressor dis-
charge pressure.
(8) Compare the discharge air temperature to the
Performance Temperature and Pressure chart. If the
discharge air temperature is high, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
Performance Temperature and Pressure
Ambient Air Temperature
and Humidity21É C
(70É F @ 80%
humidity)27É C
(80É F @ 80%
humidity)32É C
(90É F @ 80%
humidity)38É C
(100ÉF@50%
humidity)43É C
110É F @ 20%
humidity)
Air Temperature at Center
Panel Outlet10 to 13É C
(50 to 55É F)14 to 17É C
(58 to 63É F)15 to 18É C
(60 to 65É F)17 to 20É C
(63 to 68É F)14 to 17É C
(58 to 63É F)
Evaporator Inlet Pressure
at Charge Port241 to 276 kPa
(35 to 40 psi)262 to 290 kPa
(38 to 42 psi)269 to 296 kPa
(39 to 43 psi)275 to 303 kPa
(40 to 44 psi)262 to 290 kPa
(38 to 42 psi)
Compressor Discharge
Pressure1241 to 1792
kPa
(180 to 260 psi)1380 to 1930
kPa
(200 to 280 psi)1380 to 1930
kPa
(200 to 280 psi)1655 to 2206
kPa
(240 to 320 psi)1567 to 2068
kPa
(220 to 300 psi)
Note: The discharge air temperatures will be lower if the humidity is less than the percentages shown.
Fig. 2 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
WJHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)

LOCATING VACUUM LEAKS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect the vacuum harness connector from
the back of the A/C Heater mode control switch on
the control panel.
(2) Connect the test set vacuum hose probe to each
port in the vacuum harness connector, one at a time,
and pause after each connection (Fig. 2). The test set
gauge should return to the 27 kPa (8 in. Hg.) setting
shortly after each connection is made. If OK, replace
the faulty mode control switch. If not OK, go to Step
3.(3) Determine the vacuum line color of the vacuum
circuit that is leaking. To determine the vacuum line
colors, refer to the Vacuum Circuits chart (Fig. 3).
(4) Disconnect and plug the vacuum line from the
component (fitting, actuator, valve, switch, or reser-
voir) on the other end of the leaking circuit. Instru-
ment panel disassembly or removal may be necessary
to gain access to some components.
(5) Connect the test set hose or probe to the open
end of the leaking circuit. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each connection is made. If OK, replace the faulty
disconnected component. If not OK, go to Step 6.
(6) To locate a leak in a vacuum line, leave one
end of the line plugged and connect the test set hose
or probe to the other end. Run your fingers slowly
along the line while watching the test set gauge. The
vacuum reading will fluctuate when your fingers con-
tact the source of the leak. To repair the vacuum
line, cut out the leaking section of the line. Then,
insert the loose ends of the line into a suitable length
of 3 millimeter (1/8-inch) inside diameter rubber
hose.
Fig. 2 VACUUM CIRCUIT TEST
WJCONTROLS 24 - 11
CONTROLS (Continued)

open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 11).
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C HEATER CONTROL
DESCRIPTION
The manual temperature control HVAC system
uses a combination of electrical, and vacuum con-trols. The Automatic Zone Control (AZC) HVAC sys-
tem uses only electrical controls. These controls
provide the vehicle operator with a number of setting
options to help control the climate and comfort
within the vehicle. Refer to the owner's manual in
the vehicle glove box for more information on the
suggested operation and use of these controls.
Both a/c heater control panels are located on the
instrument panel inboard of the steering column and
below the radio (Fig. 12). Both control panels contain
rotary-type temperature control knob(s), a rotary-
type mode control switch knob, a rotary-type blower
motor speed switch knob and an air conditioning
compressor push button switch. The rear window
defogger push button switch is also located on a/c
heater control panel. The AZC control panel also fea-
tures a recirculation push button switch and a vac-
uum fluorescent display area.
OPERATION
The AZC control module uses infrared sensing
technology to control occupant comfort levels, not the
actual passenger compartment air temperature. Dual
infrared sensors mounted in the face of the control
unit independently measure the surface temperature
to maintain customer-perceived comfort temperature
under changing conditions. Dual Zone temperature
control provides wide side-to-side variation in comfort
temperature to exceed the needs of either front seat
occupant. This sensing system replaces interior air
temperature and solar sensors used to approximate
direct sensing control through complex control pro-
grams.
Fig. 11 POWER DISTRIBUTION CENTER (PDC)
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - NEGATIVE CABLE
3 - POSITIVE CABLE
4 - POWER DISTRIBUTION CENTER (PDC)
Fig. 12 A/C HEATER CONTROL PANELS
WJCONTROLS 24 - 17
A/C COMPRESSOR CLUTCH RELAY (Continued)

AIR INLET POINTER
63 Engine Intake Air Temperature
(in degrees F)-40 to
215
64 Vehicle speed in MPH 0 to 255
65 Engine RPM/100 -0 to 82
66 Engine Coolant Temp - 40 (in
degrees F)-40 to
215
67 Country Code 0 to 255
68 Not used 0 to 0
69 Not used 0 to 0
IR SENSOR POINTER
Pointer
NumberDESCRIPTION Value
Displayed
70 Thermistor temp (in degrees) -40 to
215
71 Left side sensor A/D (filtered) 0 to 255
72 Right side sensor A/D (filtered) 0 to 255
73 Left side temp (in degrees F) -40 to
140
74 Right side temp (in degrees F) -40 to
140
75 Not used 0 to 0
76 Not used 0 to 0
77 Not used 0 to 0
78 Not used 0 to 0
79 Not used 0 to 0
IDENTIFICATION POINTER
Pointer
NumberDESCRIPTION Value
Displayed
80 ROM bit pattern number (digits
1,2,3 & 4)0to
9999
81 ROM bit pattern number (digits
5,6,7 & 8)0to
9999
82 CAL bit pattern number (digits
1,2,3 & 4)0to
9999
83 CAL bit pattern number (digits
5,6,7 & 8)0to
9999
84 Not used 0 to 0
85 Not used 0 to 0
86 Not used 0 to 0
87 Not used 0 to 0
88 Not used 0 to 0
89 Not used 0 to 0
OUTPUT CIRCUIT/ACTUATOR TESTS
In the Output Circuit/Actuator Test mode, the out-
put circuits can be viewed, monitored, overridden,
and tested. If a failure occurs in an output circuit,
test the circuit by overriding the system. Test the
actuator through its full range of operation.
(1) To begin the Output Circuit/Actuator Tests you
must be in the Select Test mode.
(2) With a ª00º value displayed in the Test Selector
and no stick man, turn the rotary temperature con-
trol knob until the test number you are looking for
appears in the Test Selector display. See the Circuit
Testing charts for a listing of the test numbers, test
items, test types, system tested, and displayed val-
ues.
(3) To see the output value, depress the a/c or
recirc button. The values displayed will represent the
output from the AZC control module.
(4) To enter the actuator test, depress the a/c or
recirc button. Then, rotate the right temperature set
knob to the desired position.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the center upper, and center lower
bezels from the instrument panel. Refer to Instru-
ment Panel System for the procedures.
(3) Remove the 4 screws that secure the a/c heater
control to the instrument panel (Fig. 13).
(4) Pull the a/c heater control assembly away from
the instrument panel far enough to access the con-
nections on the back of the control.
(5) Unplug the wire and/or vacuum harness con-
nectors from the back of the a/c heater control (Fig.
14).
(6) Remove the a/c heater control from the instru-
ment panel.
24 - 24 CONTROLSWJ
A/C HEATER CONTROL (Continued)