2002 JEEP GRAND CHEROKEE fuel tank

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Fuel Pump Module (Gas) BK Near Fuel Tank 33, 35
Fuel Tank Module Diesel) BK Near Fuel Tank 33, 35
Generator (Diesel) LTGY At Generator 8
Generator (Gas) BK At Generator N/S
Glove Box Lamp BK Inside Glove Box 19, 20, 22
Headlamp Leveling Switch
(Built-Up-Export)WT Driver Side of Instrument Panel 20
Hood Ajar Switch BK Left Side of Engine Compartment 3, 4
Horn No.1 BK Right Front Fascia 5
Horn No.2 BK Right Front Fascia 5
Hydraulic Cooling Module BK Right Front of Engine Compartment 5
Idle Air Control Motor BK Left Side of Engine Near Throttle
Body13
Ignition Switch - C1 WT On Steering Column 23
Ignition Switch - C2 BK On Steering Column 23
Input Speed Sensor (4.7L) BK Left Side of Transmission 16
Instrument Cluster WT At Instrument Cluster 19, 20
Intake Air Temperature Sensor
(Gas)GY Left Side of Engine 9, 13
Intake Air Temperature Sensor
(Diesel)BK Near T/O for Crankcase Heater 8
Intake Port Swirl Actuator
(Diesel)BK Right Rear of Engine Compartment N/S
Intrusion Transceiver Module
(Built-up-Export)BK In The Overhead N/S
Junction Block - C1 BK At Junction Block 30, 31, 33
Junction Block - C2 BK At Junction Block 30, 31
Junction Block - C3 BK At Junction Block 21, 22, 30
Junction Block - C4 WT At Junction Block 30, 31
Junction Block - C5 WT At Junction Block 30, 31
Knock Sensor (4.7L High
Output)BK Right Rear Side of Engine, Near
Coil on Plug No.8N/S
Leak Detection Pump (Except
Built-Up-Export)Left Front Wheel Opening 3
Left Courtesy Lamp BK Left Side of Instrument Panel 21 22, 23
Left Curtain Airbag BK Near Left C Pillar 37
Left Door Handle Courtesy
LampBK At Lamp N/S
Left Fog Lamp BK At Lamp 3, 4
Left Front Door Speaker WT In Left Front Door 24, 27
Left Front Impact Sensor BK Left Front Frame Near Windshield
Washer Pump3, 4
Left Front Park Lamp WT At Lamp N/S
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT ABSORBER
REMOVAL.............................1
INSTALLATION..........................1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
REAR ABSORBER
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................4
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE.............4
FRAME DIMENSIONS...................4
FRONT SKID PLATE
REMOVAL.............................7INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
FUEL TANK SKID PLATE
DESCRIPTION..........................7
REAR TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
TRAILER HITCH
REMOVAL.............................8
INSTALLATION..........................8
TRANSFER CASE SKID PLATE
REMOVAL.............................8
INSTALLATION..........................8
FRONT ABSORBER
REMOVAL
(1) Remove front fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL).
(2) Remove the retainer attaching the absorber to
the fascia.
(3) Separate the absorber from the fascia.
INSTALLATION
(1) Position the absorber on the fascia.
(2) Install the retainer attaching the absorber to
the fascia.
(3) Install front fascia. Refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
FRONT FASCIA
REMOVAL
(1) Raise and support vehicle.
(2) Turn front wheels to access rivets and remove
plastic rivets attaching fascia to wheel liner.
(3) Remove bolts attaching fascia to fender (Fig. 1).(4) Remove plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(5) Disengage fog lamp connectors, if equipped.
(6) Remove screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(7) Slide fascia forward to separate from vehicle.
INSTALLATION
(1) Slide fascia onto vehicle engaging fascia with
tabs on bottom of front fenders.
(2) Install screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(3) Install bolts attaching fascia to fender (Fig. 1).
(4) Engage fog lamp connectors, if equipped.
(5) Install plastic rivets attaching fascia to wheel
liner.
(6) Install plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(7) Remove supports and lower vehicle.
WJFRAME & BUMPERS 13 - 1

REAR ABSORBER
REMOVAL
(1) Remove rear fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL).
(2) Remove rivets attaching absorber to rear cross-
member (Fig. 5).
(3) Separate absorber from vehicle.
INSTALLATION
(1) Position absorber on vehicle.
(2) Install rivets attaching absorber to rear cross-
member (Fig. 2).
(3) Install rear fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
INSTALLATION).
REAR FASCIA
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheels.
(3) Remove plastic push pins attaching fascia to
fuel tank skid plate.
(4) Remove plastic rivets attaching fascia to wheel
liner.
Fig. 1 Front Fascia
1 - BODY
2 - FASCIA
Fig. 2 Front Fascia
1 - WHEEL LINER
2 - FASCIA
3 - FOG LAMP CONNECTOR
4 - PLASTIC PUSH PIN
5 - PLASTIC RIVET
Fig. 3 Front Fascia
1 - SCREW
2 - FASCIA
13 - 2 FRAME & BUMPERSWJ
FRONT FASCIA (Continued)

INSTALLATION
(1) Position fascia on vehicle aligning retainers
with slots in quarter panel (Fig. 7).
(2) Press forward edges of fascia inward to engage
retainers.
(3) Install screws attaching fascia to liftgate open-
ing.
(4) Install plastic push pins attaching fascia to lift-
gate opening.
(5) Install nuts attaching upper edge of fascia to
quarter panel and wheel liner.
(6) Install plastic rivets attaching fascia to wheel
liner.
(7) Install support lower vehicle.
(8) Install plastic push pins attaching fascia to fuel
tank skid plate.
(9) Install the interior trim panels removed to
access fascia retainers.
(10) Install tie down loop screws.
(11) Install the wheels, refer to section 22 for
tightening sequence and torque specifications.
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Front Tow Hook Bolt 54 40 Ð
Front Skid Plate Bolt 54 40 Ð
Rear Tow Hook Bolt 68 50 Ð
Trailer Hitch Bolts 68 50 Ð
Transfer Case Skid Plate
Bolts34 25 Ð
FRAME DIMENSIONS
INDEX
DESCRIPTION FIGURE
SIDE VIEW 8
BOTTOM VIEW 9
Fig. 6 Rear Fascia Retainers
1 - RETAINER
2 - FASCIA
Fig. 7 Fascia Attachment
1 - SLOT
2 - QUARTER PANEL
13 - 4 FRAME & BUMPERSWJ
REAR FASCIA (Continued)

FRONT SKID PLATE
REMOVAL
(1) Position a support under skid plate.
(2) Remove bolts attaching skid plate to frame
(Fig. 10).
(3) Separate skid plate from frame.
INSTALLATION
(1) Position skid plate on a support.
(2) Raise it into position
(3) Install bolts attaching skid plate to frame.
Tighten bolts to 54 N´m (40 ft. lbs.) torque.
FRONT TOW HOOK
REMOVAL
(1) Remove bolts that attach tow hook bracket to
the lower crossmember (Fig. 11).
(2) Separate tow hook bracket from lower cross-
member.
INSTALLATION
(1) Position tow hook bracket at the lower cross-
member.
(2) Install bolts attaching tow hook bracket to
crossmember. Tighten bolts to 54 N´m (40 ft. lbs.)
torque.
FUEL TANK SKID PLATE
DESCRIPTION
The fuel tank skid plate is integrated with the fuel
tank. Refer to Fuel Tank for service procedures
REAR TOW HOOK
REMOVAL
(1) Remove rear tow hook to frame brace.
(2) Remove bolts attaching the tow hook bracket to
frame (Fig. 12).
(3) Separate tow hook bracket from frame.
INSTALLATION
(1) position tow hook bracket on frame.
(2) Install bolts attaching tow hook bracket to
frame. Tighten bolts to 68 N´m (50 ft. lbs.) torque.
(3) Install rear tow hook to frame brace.
Fig. 10 Front Skid Plate
1 - SKID PLATE
Fig. 11 Front Tow Hook
1 - TAPPING PLATE
2 - CROSSMEMBER
3 - BRACKET
4 - TOW HOOK
Fig. 12 Rear Tow Hook
1 - TOW HOOK BRACE
2 - TOW HOOK
3 - BRACKET
4 - FUEL TANK
WJFRAME & BUMPERS 13 - 7

TRAILER HITCH
REMOVAL
(1) Remove rear fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL).
(2) Remove screws attaching trailer harness plug
to trailer hitch.
(3) Disconnect harness connector from harness
plug.
(4) Position support stands under trailer hitch.
(5) Remove bolts attaching trailer hitch to frame
rails (Fig. 13).
(6) Separate trailer hitch from vehicle.
INSTALLATION
(1) Position trailer hitch on support stands.
(2) Position trailer hitch on vehicle.
(3) Install bolts attaching trailer hitch to frame
rails. Tighten bolts to 68 N´m (50 lbs.) torque.(4) Connect harness connector to harness plug.
(5) Position harness plug in trailer hitch and
install screws.
(6) Install rear fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
INSTALLATION).
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support skid plate.
(2) Remove bolts that attach skid plate to trans-
mission support crossmember and frame sill (Fig.
14).
(3) Remove support and skid plate from vehicle.
INSTALLATION
(1) Install nutserts, if removed.
(2) Position and support skid plate at the frame
sill and transmission support crossmember.
(3) Attach skid plate to frame sill and crossmem-
ber with the bolts. Tighten bolts to 34 N´m (25 ft. lbs)
torque.
Fig. 13 Trailer Hitch
1 - FUEL TANK
2 - TRAILER HITCH
Fig. 14 Transfer Case Skid Plate
1 - TRANSFER CASE
2 - NUTSERT
3 - SKID PLATE
4 - CROSSMEMBER
13 - 8 FRAME & BUMPERSWJ

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................31
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING
FUEL PRESSURE LEAK DOWN TEST......2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE...................4
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............4
TORQUE - FUEL DELIVERY..............4
SPECIAL TOOLS
FUEL SYSTEM........................5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................6
INSTALLATION..........................6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT........................7
REMOVAL.............................7
INSTALLATION..........................8
FUEL LINES
DESCRIPTION..........................8
FUEL PUMP
DESCRIPTION..........................8
OPERATION............................9
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST.......................9
DIAGNOSIS AND TESTING - FUEL PUMP
AMPERAGE TEST......................9FUEL PUMP PRESSURE TEST...........11
FUEL PUMP MODULE
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................14
FUEL RAIL
DESCRIPTION
DESCRIPTION - 4.7L...................15
DESCRIPTION - 4.0L...................15
OPERATION
OPERATION - 4.7L....................15
OPERATION - 4.0L....................15
REMOVAL
REMOVAL - 4.7L......................15
REMOVAL - 4.0L......................17
INSTALLATION
INSTALLATION - 4.7L..................18
INSTALLATION - 4.0L..................18
FUEL TANK
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
INLET FILTER
REMOVAL.............................27
INSTALLATION.........................27
QUICK CONNECT FITTING
DESCRIPTION.........................27
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS...........................27
WJFUEL SYSTEM 14 - 1

FUEL DELIVERY
DESCRIPTION
The fuel delivery system consists of:
²the fuel pump module containing the electric
fuel pump, fuel gauge sending unit (fuel level sensor)
and a separate fuel filter located at bottom of pump
module
²a separate combination fuel filter/fuel pressure
regulator
²fuel tubes/lines/hoses
²quick-connect fittings
²fuel injector rail
²fuel injectors
²fuel tank
²fuel tank filler/vent tube assembly
²fuel tank filler tube cap
²accelerator pedal
²throttle cable
OPERATION
The fuel tank assembly consists of: the fuel tank,
fuel tank shield, fuel tank straps, fuel pump module
assembly, fuel pump module locknut/gasket, and fuel
tank check valve (refer to Emission Control System
for fuel tank check valve information).
A fuel filler/vent tube assembly using a pressure/
vacuum, 1/4 turn fuel filler cap is used. The fuel
filler tube contains a flap door located below the fuel
fill cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-
sphere. The description and function of the Evapora-
tive Control System is found in Emission Control
Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
DIAGNOSIS AND TESTING
FUEL PRESSURE LEAK DOWN TEST
Use this test in conjunction with the Fuel Pump
Pressure Test and Fuel Pump Capacity Test.
Check Valve Operation:The electric fuel pump
outlet contains a one-way check valve to prevent fuel
flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not oper-
ational. It is also used to keep the fuel supply line
full of gasoline when pump is not operational. After
the vehicle has cooled down, fuel pressure may drop
to 0 psi (cold fluid contracts), but liquid gasoline willremain in fuel supply line between the check valve
and fuel injectors.Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition.When the elec-
tric fuel pump is activated, fuel pressure should
immediately(1±2 seconds) rise to specification.
Abnormally long periods of cranking to restart a
hotengine that has been shut down for a short
period of time may be caused by:
²Fuel pressure bleeding past a fuel injector(s).
²Fuel pressure bleeding past the check valve in
the fuel pump module.
²A defective fuel filter/pressure regulator.
Two #6539, 5/16º, Fuel Line Pressure Test Adapter
Hose Tools are required for the following tests.
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure.
(2) Raise vehicle.
Fuel Line Identification:The fuel filter/pressure
regulator is located in front of the fuel tank and
above the rear axle. It is transversely mounted to a
chassis crossmember (left-to-right). The filter/regula-
tor is equipped with 3 fuel line fittings (2 at one end
and 1 at the other end). The single fitting facing the
left side of the vehicle is the supply line to the fuel
rail (Fig. 1) . The 2 fittings facing the right side of
the vehicle are connected to the fuel tank. Of these 2
fittings, the fitting towards thefrontis used for fuel
return to the fuel tank. The fitting towards therear
is a pressure line. Thisrearfitting must be discon-
nected for the following step.
(3) See previous step. Disconnect fuel pressure line
atrearof filter/regulator. This is a 5/169quick-con-
nect fitting (Fig. 1) . Refer to Quick-Connect Fittings
for procedures.
(4) Obtain correct Fuel Line Pressure Test Adapter
Hose Tool # 6539 for 5/16º fuel lines. Connect one
end of this Special Tool into the disconnected fuel
pressure line. Connect the other end of the Tool into
fitting on filter/regulator.
(5) Lower vehicle.
(6) Disconnect the fuel inlet line at fuel rail. Refer
to Quick-Connect Fittings for procedures. On some
engines, air cleaner housing removal may be neces-
sary before fuel line disconnection.
(7) Obtain a second Fuel Line Pressure Test
Adapter Hose Tool # 6539 for 5/16º fuel lines. Con-
nect this tool between disconnected fuel line and fuel
rail (Fig. 2) .
(8) Connect the 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool.NOTE: The DRB III
Scan Tool along with the PEP module, the 500
psi pressure transducer, and the transducer-to-
test port adapter may also be used in place of
the fuel pressure gauge.
14 - 2 FUEL DELIVERYWJ