2002 JEEP GRAND CHEROKEE 100

(5) Install and tighten the nut that secures the
battery positive cable eyelet terminal to the B(+) ter-
minal stud on the starter solenoid. Tighten the nut to
11.3 N´m (100 in. lbs.).
(6) Install and tighten the screw that secures the
battery negative cable ground eyelet terminal to the
right side of the engine block. Tighten the screw to
10.2 N´m (90 in. lbs.) for 4.0L engines, or 13.0 N´m
(115 in. lbs.) for 4.7L engines.
(7) Reconnect the battery wire harness connector
to the generator field terminal connector receptacle
on the back of the generator.
(8) Install the generator output cable eyelet termi-
nal onto the generator output terminal stud.
(9) Install and tighten the nut that secures the
generator output cable eyelet terminal to the genera-
tor output terminal stud. Tighten the nut to 10.7
N´m (95 in. lbs.).
(10) Position the cover for the generator output
terminal stud housing onto the back of the generator
and snap it into place.
(11) On models with the 4.7L engine, install the
battery harness clip onto the stud on the right side of
the intake manifold, then install and tighten the nut
that secures the clip to the stud. Tighten the nut to
11.3 N´m (100 in. lbs.).
(12) Install and tighten the screw that secures the
battery negative cable eyelet terminal to the inner
fender shield near the front of the battery. Tighten
the screw to 28.2 N´m (250 in. lbs.).(13) Reconnect the battery wire harness connector
to the right headlamp and dash wire harness connec-
tor located near the front of the battery.
(14) Install the battery positive cable and genera-
tor output cable eyelet terminal onto the PDC B(+)
terminal studs.
(15) Install and tighten the two nuts that secure
the battery positive cable and generator output cable
eyelet terminal to the PDC B(+) terminal studs.
Tighten the nuts to 11.3 N´m (100 in. lbs.).
(16) Close and latch the PDC cover.
(17) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 6.8 N´m (60
in. lbs.).
(18) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 6.8 N´m (60
in. lbs.).
(19) Apply a thin coating of petroleum jelly or
chassis grease to the exposed surfaces of the battery
cable terminal clamps and the battery terminal
posts.BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic battery
tray and support unit (Fig. 25) located in the right
front corner of the engine compartment. The battery
tray and support unit is secured at the rear with a
nut to a stud on the front wheelhouse inner panel, at
the outboard side with a screw to the side cowl rein-
forcement panel, and at the front with a screw
through a U-nut on a bracket of the radiator support.
The battery tray and support unit also includes
three upright stanchions that are molded into the
outboard side of the unit. These stanchions support
the Power Distribution Center (PDC). Refer to
Power Distribution Centerin the Power Distribu-
tion section of this service manual for more informa-
tion on the PDC.
A hole in the bottom of the battery tray is fitted
with a battery temperature sensor. Refer toBattery
Temperature Sensorin the Charging section of
this service manual for more information on the bat-
tery temperature sensor. Refer toBattery Hold
Downin this section of the service manual for more
information on the battery hold down hardware.
Fig. 24 Battery Cables - 4.7L Engine
1 - BATTERY POSITIVE CABLE
2 - BATTERY NEGATIVE CABLE
3 - CLIPS
WJBATTERY SYSTEM 8F - 21
BATTERY CABLE (Continued)

²a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test in 8, Battery for more information.
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBtscan tool. Per-
form the following inspections before attaching the
scan tool.(1) Inspect the battery condition. Refer to 8, Bat-
tery for procedures.
(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications.
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications in 7, Cooling System.
(6) Inspect automatic belt tensioner (if equipped).
Refer to 7, Cooling System for information.
(7) Inspect generator electrical connections at gen-
erator field, battery output, and ground terminal (if
equipped). Also check generator ground wire connec-
tion at engine (if equipped). They should all be clean
and tight. Repair as required.
SPECIFICATIONS
GENERATOR RATINGS - GAS POWERED
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
BOSCH 56041322 136 4.0L 6-Cylinder 100
DENSO 56041324 136 4.7L V-8 100
TORQUE - GAS POWERED
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Generator Mounting Bolts-4.0L 55 41
Generator Vertical Mounting Bolt-4.7L 40 29
Generator (long) Horizontal Mounting
Bolt-4.7L55 41
Generator (short) Horizontal Mounting
Bolt-4.7L55 41
Generator B+ Terminal Nut 11 95
WJCHARGING 8F - 25
CHARGING (Continued)

INSTALLATION
(1) Position generator to engine and install mount-
ing bolts.
(2) Tighten generator mounting bolts as follows:
²Vertical mounting bolt 4.7L engineÐ40 N´m (29
ft. lbs.)
²Long horizontal mounting bolt 4.7L engineÐ55
N´m (41 ft. lbs.)
²Short horizontal mounting bolt 4.7L engineÐ55
N´m (41 ft. lbs.)
²Generator mounting bolts 4.0L engineÐ55 N´m
(41 ft. lbs.)
²B+ terminal nutÐ11 N´m (95 in. lbs.)
(3) Snap 2±wire field connector into rear of gener-
ator.
(4) Snap cable protector cover to B+ mounting
stud.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(6) Install negative battery cable to battery.
VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more information). It then determines a
target charging voltage. If sensed battery voltage is
0.5 volts or lower than the target voltage, the PCM
grounds the field winding until sensed battery volt-
age is 0.5 volts above target voltage. A circuit in the
PCM cycles the ground side of the generator field up
to 100 times per second (100Hz), but has the capabil-
ity to ground the field control wire 100% of the time
(full field) to achieve the target voltage. If the charg-
ing rate cannot be monitored (limp-in), a duty cycle
of 25% is used by the PCM in order to have some
generator output. Also refer to Charging System
Operation for additional information.
Fig. 4 Remove/Install GeneratorÐ4.0L 6±Cylinder
Engine
1 - GENERATOR
2 - UPPER BOLT
3 - LOWER BOLT
8F - 28 CHARGINGWJ
GENERATOR (Continued)

SPECIFICATIONS
TORQUE - STARTER
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Stater Motor (B+) Terminal
(Diesel)27 20
Stater Motor (B+) Terminal
(Except Diesel)11.3 100
Starter Motor Retaining Bolts
(Diesel)27 20
Starter Motor Retaining Bolt
(Forward Facing 4.0L)41 30
Starter Motor Retaining Bolt
(Forward Facing 4.7L)54 40
Starter Motor Retaining Bolt
(Rearward Facing 4.7L)54 40
STARTER MOTOR - GAS POWERED
Starter Motor and Solenoid
Manufacturer Mitsubishi
Engine Application 4.0L/4.7L
Power Rating 1.4 Kilowatt (1.9 Horsepower)
Voltage12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
Free Running Test Minimum Speed 2400 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
*Cranking Amperage Draw Test 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
STARTER MOTOR
DESCRIPTION
The starter motors used for both the 4.0L and the
4.7L engines available in this model are very similar,
but are not interchangeable. Both starter motors are
mounted with two screws to the automatic transmis-
sion torque converter housing and are located on the
right side of the engine.
Each of these starter motors incorporates several
of the same features to create a reliable, efficient,compact, lightweight and powerful unit. The electric
motors of both starters feature four electromagnetic
field coils wound around four pole shoes, and four
brushes contact the motor commutator. Both starter
motors are rated at 1.4 kilowatts (about 1.9 horse-
power) output at 12 volts.
Both of these starter motors are serviced only as a
unit with their starter solenoids, and cannot be
repaired. If either component is faulty or damaged,
the entire starter motor and starter solenoid unit
must be replaced.
WJSTARTING 8F - 35
STARTING (Continued)

OPERATION
These starter motors are equipped with a plane-
tary gear reduction (intermediate transmission) sys-
tem. The planetary gear reduction system consists of
a gear that is integral to the output end of the elec-
tric motor armature shaft that is in continual
engagement with a larger gear that is splined to the
input end of the starter pinion gear shaft. This fea-
ture makes it possible to reduce the dimensions of
the starter. At the same time, it allows higher arma-
ture rotational speed and delivers increased torque
through the starter pinion gear to the starter ring
gear.
The starter motors for both engines are activated
by an integral heavy duty starter solenoid switch
mounted to the overrunning clutch housing. This
electromechanical switch connects and disconnects
the feed of battery voltage to the starter motor and
actuates a shift fork that engages and disengages the
starter pinion gear with the starter ring gear.
Both starter motors use an overrunning clutch and
starter pinion gear unit to engage and drive a starter
ring gear that is integral to the torque converter
drive plate mounted on the rear crankshaft flange.
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with the starter
motor removed from the vehicle. Refer toStarting
Systemin the Specifications section of this group for
the starter motor specifications.
(1) Remove the starter motor from the vehicle.
Refer toStarter Motorin the Removal and Instal-
lation section of this group for the procedures.
(2) Mount the starter motor securely in a soft-
jawed bench vise. The vise jaws should be clamped
on the mounting flange of the starter motor. Never
clamp on the starter motor by the field frame.
(3) Connect a suitable volt-ampere tester and a
12-volt battery to the starter motor in series, and set
the ammeter to the 100 ampere scale. See the
instructions provided by the manufacturer of the
volt-ampere tester being used.
(4) Install a jumper wire from the solenoid termi-
nal to the solenoid battery terminal. The starter
motor should operate. If the starter motor fails to
operate, replace the faulty starter motor assembly.
(5) Adjust the carbon pile load of the tester to
obtain the free running test voltage. Refer toStart-
ing Systemin the Specifications section of this
group for the starter motor free running test voltage
specifications.
(6) Note the reading on the ammeter and compare
this reading to the free running test maximum
amperage draw. Refer toStarting Systemin theSpecifications section of this group for the starter
motor free running test maximum amperage draw
specifications.
(7) If the ammeter reading exceeds the maximum
amperage draw specification, replace the faulty
starter motor assembly.
STARTER SOLENOID
This test can only be performed with the starter
motor removed from the vehicle.
(1) Remove the starter motor from the vehicle.
Refer toStarter Motorin the Removal and Instal-
lation section of this group for the procedures.
(2) Disconnect the wire from the solenoid field coil
terminal.
(3) Check for continuity between the solenoid ter-
minal and the solenoid field coil terminal with a con-
tinuity tester (Fig. 7). There should be continuity. If
OK, go to Step 4. If not OK, replace the faulty starter
motor assembly.
(4) Check for continuity between the solenoid ter-
minal and the solenoid case (Fig. 8). There should be
continuity. If not OK, replace the faulty starter motor
assembly.
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - Typical
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL
Fig. 8 Continuity Test Between Solenoid Terminal
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
8F - 36 STARTINGWJ
STARTER MOTOR (Continued)

(8) Remove the starter motor from the engine com-
partment.
INSTALLATION
(1) Position the starter motor in the engine com-
partment.
(2) Reconnect the solenoid terminal wire harness
connector to the connector receptacle on the starter
solenoid. Always support the starter motor during
this process, do not let the starter motor hang from
the wire harness.
(3) Install the battery cable eyelet onto the sole-
noid battery terminal. Always support the starter
motor during this process, do not let the starter
motor hang from the wire harness.
(4) Install and tighten the nut that secures the
battery cable eyelet to the solenoid battery terminal.
Tighten the nut to 11.3 N´m (100 in. lbs.). Always
support the starter motor during this process, do not
let the starter motor hang from the wire harness.
(5) Position the starter motor to the front of the
automatic transmission torque converter housing and
loosely install both the upper and lower mounting
screws.
(6) Tighten the lower (forward facing) starter
motor mounting screw. On 4.0L engines, tighten the
screw to 41 N´m (30 ft. lbs.). On 4.7L engines, tighten
the screw to 54 N´m (40 ft. lbs.).(7) Tighten the upper (rearward facing) starter
mounting screw. Tighten the screw to 54 N´m (40 ft.
lbs.).
(8) Lower the vehicle.
(9) Reconnect the battery negative cable.
STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when the ignition switch is turned to
the Start position. The starter relay is located in the
Power Distribution Center (PDC), in the engine com-
partment. See the fuse and relay layout label affixed
to the inside surface of the PDC cover for starter
relay identification and location.
The starter relay is a International Standards
Organization (ISO) micro-relay. Relays conforming to
the ISO specifications have common physical dimen-
sions, current capacities, terminal patterns, and ter-
minal functions. The ISO micro-relay terminal
functions are the same as a conventional ISO relay.
However, the ISO micro-relay terminal pattern (or
footprint) is different, the current capacity is lower,
and the physical dimensions are smaller than those
of the conventional ISO relay.
The starter relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter relay (Fig. 13) is located in the Power
Distribution Center (PDC), in the engine compart-
ment. Refer to the fuse and relay layout label affixed
to the underside of the PDC cover for starter relay
identification and location. For complete circuit dia-
grams, refer toStarting Systemin the Contents of
Group 8W - Wiring Diagrams.
Fig. 12 Starter Wire Harness Remove/Install - 4.7L
Engine
1 - SOLENOID BATTERY TERMINAL EYELET
2 - NUT
3 - SOLENOID TERMINAL CONNECTOR
4 - BATTERY STARTER AND GENERATOR WIRE HARNESS
5 - RETAINERS
8F - 38 STARTINGWJ
STARTER MOTOR (Continued)

(6) Remove both horns and the mounting bracket
from the right extension of the radiator closure
assembly as a unit.
INSTALLATION
(1) Position both horns and the mounting bracket
onto the right extension of the radiator closure
assembly as a unit.
(2) Install and tighten the screw that secures the
horn mounting bracket to the right extension of the
radiator closure assembly. Tighten the screw to 11.3
N´m (100 in. lbs.).
(3) Reconnect the two right headlamp and dash
wire harness connectors to the horn connector recep-
tacles. Be certain to engage the connector lock tabs
after reconnecting them to the horn connector recep-
tacles.
(4) Install the lower front half of the inner liner to
the right front fender wheel house. (Refer to 23 -
BODY/EXTERIOR/FRONT FENDER - INSTALLA-
TION) for the procedure.
(5) Lower the vehicle.
(6) Reconnect the battery negative cable.
HORN RELAY
DESCRIPTION
The horn relay is a electromechanical device that
switches battery current to the horn when the horn
switch grounds the relay coil. The horn relay is
located in the Power Distribution Center (PDC) inthe engine compartment. If a problem is encountered
with a continuously sounding horn, it can usually be
quickly resolved by removing the horn relay from the
PDC until further diagnosis is completed. See the
fuse and relay layout label affixed to the inside sur-
face of the PDC cover for horn relay identification
and location.
The horn relay is a International Standards Orga-
nization (ISO) micro-relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions. The ISO micro-relay terminal functions
are the same as a conventional ISO relay. However,
the ISO micro-relay terminal pattern (or footprint) is
different, the current capacity is lower, and the phys-
ical dimensions are smaller than those of the conven-
tional ISO relay.
The horn relay cannot be repaired or adjusted and,
if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING - HORN RELAY
The horn relay (Fig. 2) is located in the Power Dis-
tribution Center (PDC) between the battery and the
right inner fender shield on the passenger side of the
engine compartment. If a problem is encountered
with a continuously sounding horn, it can usually be
quickly resolved by removing the horn relay from the
PDC until further diagnosis is completed. See the
fuse and relay layout label affixed to the inside sur-
face of the PDC cover for horn relay identification
and location. For complete circuit diagrams, refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
Fig. 1 Horns Remove/Install
1 - RADIATOR CLOSURE ASSEMBLY
2 - HORNS AND MOUNTING BRACKET
3 - RIGHT HEADLAMP AND DASH WIRE HARNESS
CONNECTORS
8H - 4 HORNWJ
HORN (Continued)

INSTALLATION
4.7L High-Output Engine Only
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Thoroughly clean knock sensor mounting holes.
(2) Install sensors (Fig. 22) into cylinder block.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) Install and tighten mounting bolts.Bolt
torque is critical.Refer to torque specification.
(4) Install intake manifold. Refer to Engine sec-
tion.
(5) Connect knock sensor pigtail wiring harness to
engine wiring harness near right / rear of intake
manifold (Fig. 23).
SPARK PLUG
DESCRIPTION
Both the 4.0L 6-cylinder and the 4.7L V-8 engine
use resistor type spark plugs. Standard 4.7L V-8
engines are equipped with ªfired in suppressor sealº
type spark plugs using a copper core ground elec-
trode. High-Output (H.O.) 4.7L V-8 engines are
equipped with unique plugs using a platinum rivet
located on the tip of the center electrode.
Because of the use of an aluminum cylinder head
on the 4.7L engine, spark plug torque is very critical.
To prevent possible pre-ignition and/or mechanical
engine damage, the correct type/heat range/number
spark plug must be used.Do not substitute any
other spark plug on the 4.7L H.O. engine. Seri-
ous engine damage may occur.
Plugs on both engines have resistance values rang-
ing from 6,000 to 20,000 ohms (when checked with at
least a 1000 volt spark plug tester).Do not use an
ohmmeter to check the resistance values of thespark plugs. Inaccurate readings will result.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-
gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O, Lubrication and Maintenance.
EXCEPT 4.7L H.O. ENGINE :Spark plugs that
have low mileage may be cleaned and reused if not
otherwise defective, carbon or oil fouled. Also refer to
Spark Plug Conditions.4.7L H.O. ENGINE :Never
clean spark plugs on the 4.7L H.O. engine. Damage
to the platinum rivet will result.
CAUTION: EXCEPT 4.7L H.O. ENGINE : Never use a
motorized wire wheel brush to clean the spark
plugs. Metallic deposits will remain on the spark
plug insulator and will cause plug misfire.
H.O. Gap Adjustment:If equipped with the 4.7L
H.O. engine, do not use a wire-type gapping tool as
damage to the platinum rivet on the center electrode
may occur. Use a tapered-type gauge (Fig. 24).
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
Fig. 24 PLUG GAP - 4.7L H.O.
1 - TAPER GAUGE
WJIGNITION CONTROL 8I - 15
KNOCK SENSOR (Continued)