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Page 1184 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Passenger Power Seat Rear
Riser MotorRD At Passenger Seat N/S
Passenger Power Seat
Recliner Motor (Midline/
Premium)BK At Passenger Seat N/S
Passenger Power S

Page 1185 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Right Front Park/Turn Signal
Lamp (Except Built-Up-Export)BK At Lamp N/S
Right Front Side Marker Lamp
(Except Built-Up-Export)WT At Lamp N/S
Right Front Turn

Page 1186 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Trailer Tow Brake Lamp Relay BK Left Quarter Panel N/S
Trailer Tow Circuit Breaker BK Left Quarter Panel N/S
Trailer Tow Connector BK In Rear Bumper 39
Traile

Page 1272 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (2) Remove cap screws, bridge and pivot assem-
blies and rocker arms (Refer to 9 - ENGINE/CYLIN-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL) for access to each valve spring to be
removed.
(3) Remov

(2) Remove cap screws, bridge and pivot assem-
blies and rocker arms (Refer to 9 - ENGINE/CYLIN-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL) for access to each valve spring to be
removed.
(3) Remove push rods.Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Remove the spark plug(s) adjacent to the cylin-
der(s) below the valve springs to be removed.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
against their seats. For vehicles equipped with an air
conditioner, use a flexible air adaptor when servicing
the No.1 cylinder.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool MD-998772A to compress the spring
and remove the locks (Fig. 27).
(8) Remove valve spring and retainer (Fig. 27).
(9) Remove valve stem oil seals (Fig. 27). Note the
valve seals are different for intake and exhaust
valves. The top of each seal is marked either INT
(intake/black in color) or EXH (exhaust/brown in
color). DO NOT mix the seals.
INSTALLATION
NOTE: This procedure can be done with the engine
cylinder head installed on the block.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Lightly push the valve seal over the valve stem
and valve guide boss. Be sure the seal is completely
seated on the valve guide boss.
(2) Install valve spring and retainer (Fig. 28).
(3) Compress the valve spring with Valve Spring
Compressor Tool MD-998772A and insert the valve
locks. Release the spring tension and remove the
tool. Tap the spring from side-to-side to ensure that
the spring is seated properly on the engine cylinder
head.(4) Release air pressure and disconnect the air
hose. Remove the adaptor from the spark plug hole
and install the spark plug.
(5) Repeat the procedures for each remaining valve
spring to be removed.
(6) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet.
(7) Install the rocker arms, pivots and bridge
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - INSTALLATION) at their
original location.
(8) Install the engine cylinder head cover (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
Fig. 27 Valve and Valve Components
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
WJENGINE - 4.0L 9 - 29
VALVE SPRINGS (Continued)

Page 1278 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual is needed to provide the correct clearance. Refer to
CONNECTING ROD BEARING FITTING CHART .
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter

is needed to provide the correct clearance. Refer to
CONNECTING ROD BEARING FITTING CHART .
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow53.2257 - 53.2079 mm
Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange53.2079 - 53.1901 mm
Yellow - StandardBlue - Undersize (2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize (2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red52.9717 - 52.9539 mm
Red - Undersize Red - Undersize (2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11)FOR EXAMPLE:If the initial clearance was
0.0762 mm (0.003 inch), 0.025 mm (0.001 inch)
undersize inserts would reduce the clearance by
0.025 mm (0.001 inch). The clearance would be 0.002
inch and within specification. A 0.051 mm (0.002
inch) undersize insert would reduce the initial clear-
ance an additional 0.013 mm (0.0005 inch). The
clearance would then be 0.038 mm (0.0015 inch).
(12) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(13) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 45 N´m (33 ft. lbs.) torque.
SIDE CLEARANCE MEASUREMENT
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange (Fig. 40).
(Refer to 9 - ENGINE - SPECIFICATIONS). Replace
the connecting rod if the side clearance is not within
specification.
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a crosshaped four throw design
with eight counterweights for balancing purposes.The crankshaft is supported by seven select main
bearings with the number three serving as the thrust
washer location. The main journals of the crankshaft
are cross drilled to improve rod bearing lubrication.
The select fit main bearing markings are located on
the crankshaft counter weights. The crankshaft rear
oil seal is a two piece design. The front oil seal is a
one piece design retained in the timing chain cover
(Fig. 41).
Fig. 40 Checking Connecting Rod Side Clearance -
Typical
WJENGINE - 4.0L 9 - 35
CONNECTING ROD BEARINGS (Continued)

Page 1279 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The main bearing caps, numbered (front to rear)
from 1 through 7 have an arrow to

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The main bearing caps, numbered (front to rear)
from 1 through 7 have an arrow to indicate the for-
ward position. The upper main bearing inserts are
grooved to provide oil channels while the lower
inserts are smooth.
Each bearing insert pair is selectively fitted to its
respective journal to obtain the specified operating
clearance. In production, the select fit is obtained by
using various-sized color-coded bearing insert pairs
as listed in the Main Bearing Fitting Chart. The
bearing color code appears on the edge of the insert.
The size is not stamped on bearing inserts used
for engine production.
The main bearing journal size (diameter) is identi-
fied by a color-coded paint mark (Fig. 42)on the adja-
cent cheek or counterweight towards the rear of the
crankshaft (flange end). The rear main journal, is
identified by a color-coded paint mark on the crank-
shaft rear flange.
When required, upper and lower bearing inserts of
different sizes may be used as a pair. A standard size
insert is sometimes used in combination with a 0.025
mm (0.001 inch) undersize insert to reduce the clear-
ance by 0.013 mm (0.0005 inch).Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the bearings have been properly fitted, (Refer
to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT
MAIN BEARINGS - INSTALLATION).
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When using Plastigage, check only one bearing
clearance at a time.
Install the grooved main bearings into the cylinder
block and the non-grooved bearings into the bearing
caps.
Install the crankshaft into the upper bearings dry.
Place a strip of Plastigage across full width of the
crankshaft journal to be checked.
Install the bearing cap and tighten the bolts to 108
N´m (80 ft. lbs.) torque.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the bearing cap. Determine the amount of
clearance by measuring the width of the compressed
Plastigage with the scale on the Plastigage envelope
(Fig. 43). (Refer to 9 - ENGINE - SPECIFICATIONS)
for the proper clearance.
Plastigage should indicate the same clearance
across the entire width of the insert. If clearance var-
ies, it may indicate a tapered journal or foreign
material trapped behind the insert.
If the specified clearance is indicated and there are
no abnormal wear patterns, replacement of the bear-
ing inserts is not necessary. Remove the Plastigage
from the crankshaft journal and bearing insert. Pro-
ceed to (Refer to 9 - ENGINE/ENGINE BLOCK/
CRANKSHAFT MAIN BEARINGS -
INSTALLATION).
If the clearance exceeds specification, install a pair
of 0.025 mm (0.001 inch) undersize bearing inserts
and measure the clearance as described in the previ-
ous steps.
The clearance indicate with the 0.025 mm (0.001
inch) undersize insert pair installed will determine if
this insert size or some other combination will pro-
vide the specified clearance.FOR EXAMPLE:If the
clearance was 0.0762 mm (0.003 inch) originally, a
pair of 0.0254 mm (0.001 inch) undersize inserts
would reduce the clearance by 0.0254 mm (0.001
inch). The clearance would then be 0.0508 mm (0.002
inch) and within the specification. A 0.051 mm (0.002
inch) undersize bearing insert and a 0.0254 mm
(0.001 inch) undersize insert would reduce the origi-
Fig. 41 Crankshaft with Select Fit Marking Location
1 - 1/4º LETTERS
2 - (ROD)
3 - (MAIN)
9 - 36 ENGINE - 4.0LWJ
CRANKSHAFT (Continued)

Page 1281 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow63.5025 -63.4898 mm
Yellow - Standard Yellow -

Page 1289 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (11) Lower the vehicle until it is about 2 feet from
the floor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, sli

(11) Lower the vehicle until it is about 2 feet from
the floor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) Have an assistant push the piston and con-
necting rod assemblies up and through the top of the
cylinder bores (Fig. 60).
INSTALLATION
(1) Clean the cylinder bores thoroughly. Apply a
light film of clean engine oil to the bores with a clean
lint-free cloth.
(2) Install the piston rings on the pistons if
removed (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON RINGS - STANDARD PROCEDURE).
(3) Lubricate the piston and rings with clean
engine oil.
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.(4) Use a piston ring compressor to install the con-
necting rod and piston assemblies through the top of
the cylinder bores (Fig. 61).
(5) Ensure the arrow on the piston top points to
the front of the engine (Fig. 61).
(6) Raise the vehicle.
(7) Each bearing insert is fitted to its respective
journal to obtain the specified clearance between the
bearing and the journal. In production, the select fit
is obtained by using various-sized, color-coded bear-
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of
the bearing insert. The size is not stamped on inserts
used for production of engines.
(8) The rod journal is identified during the engine
production by a color-coded paint mark on the adja-
cent cheek or counterweight toward the flange (rear)
end of the crankshaft. The color codes used to indi-
cate journal sizes are listed in the Connecting Rod
Bearing Fitting Chart.
(9) When required, upper and lower bearing
inserts of different sizes may be used as a pair (refer
to Connecting Rod Bearing Fitting Chart). A stan-
dard size insert is sometimes used in combination
with a 0.025 mm (0.001 inch) undersize insert to
reduce clearance 0.013 mm (0.0005 inch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) Install the connecting rod bearing caps and
inserts in the same positions as removed.
CAUTION: Verify that the oil squirt holes in the rods
face the camshaft and that the arrows on the pis-
tons face the front of the engine.
(11) Install main bearing cap brace (Fig. 58).
Tighten nuts to 47 N´m (35 ft. lbs.).
Fig. 60 Removal of Connecting Rod and Piston
Assembly
1 - PISTON
2 - CONNECTING ROD
3 - BLOCK
Fig. 61 Rod and Piston Assembly Installation
9 - 46 ENGINE - 4.0LWJ
PISTON & CONNECTING ROD (Continued)

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