2002 JEEP GRAND CHEROKEE Outlet

the vehicle. The power outlet base and mount are
secured by a snap fit within the quarter trim panel.
A plastic protective cap snaps into the power outlet
base when the power outlet is not being used, and
hangs from the power outlet base mount by an inte-
gral bail strap while the power outlet is in use. While
the power outlet is very similar to a cigar lighter
base unit, it does not include the two small spring-
clip retainers inside the bottom of the receptacle
shell that are used to secure the cigar lighter heating
element to the insulated contact.
The power outlet receptacle unit and the accessory
power outlet protective cap are available for service.
The power outlet receptacle cannot be repaired and,
if faulty or damaged, it must be replaced.
OPERATION - REAR POWER OUTLET
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet receives battery voltage from a fuse
in the Power Distribution Center (PDC) through a
fuse in the Junction Block (JB) at all times. Refer to
Horn/Cigar Lighter/Power Outletin Wiring Dia-
grams for the location of complete rear power outlet
circuit diagrams.
DIAGNOSIS AND TESTING - REAR POWER
OUTLET
Refer toHorn/Cigar Lighter/Power Outletin
Wiring Diagrams for the location of complete rear
power outlet circuit diagrams.
(1) Check the fused B(+) fuse in the Junction
Block (JB). If OK, go to Step 2. If not OK, repair the
shorted circuit or component as required and replace
the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the JB. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the Power Distribution
Center (PDC) as required.
(3) Remove the plastic protective cap from the rear
power outlet receptacle. Check for continuity between
the inside circumference of the rear power outlet
receptacle and a good ground. There should be conti-
nuity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the rear power outlet
receptacle. If not OK, go to Step 5.(5) Disconnect and isolate the battery negative
cable. Remove the rear power outlet from the right
quarter trim panel. Check for continuity between the
ground circuit cavity of the rear power outlet wire
harness connector and a good ground. There should
be continuity. If OK, go to Step 6. If not OK, repair
the open ground circuit to ground as required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
rear power outlet wire harness connector. If OK,
replace the faulty rear power outlet receptacle base.
If not OK, repair the open fused B(+) circuit to the
JB fuse as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the protective cap out of the rear power
outlet receptacle base (Fig. 20).
Fig. 20 Rear Power Outlet Remove/Install
1 - RIGHT QUARTER TRIM PANEL
2 - RIGHT BODY WIRE HARNESS CONNECTOR
3 - RECEPTACLE BASE
4 - PROTECTIVE CAP
5 - MOUNT
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 17
REAR POWER OUTLET (Continued)

(3) Look inside the rear power outlet receptacle
base and note the position of the rectangular retain-
ing bosses of the mount that secures the receptacle
base to the right quarter trim panel (Fig. 21).(4) Insert a pair of external snap ring pliers into
the rear power outlet receptacle base and engage the
tips of the pliers with the retaining bosses of the
mount.
(5) Squeeze the pliers to disengage the mount
retaining bosses from the receptacle base and, using
a gentle rocking motion, pull the pliers and the
receptacle base out of the mount.
(6) Pull the rear power outlet receptacle base away
from the right quarter trim panel far enough to
access the wire harness connector.
(7) Disconnect the right body wire harness connec-
tor from the rear power outlet receptacle base con-
nector receptacle.
(8) Remove the rear power outlet mount from the
right quarter trim panel.
INSTALLATION
(1) Align the splines on the outside of the rear
power outlet receptacle base connector receptacle
with the grooves on the inside of the mount.
(2) Insert the rear power outlet receptacle base
about half way through the mount.
(3) Reconnect the right body wire harness connec-
tor to the rear power outlet receptacle base connector
receptacle.
(4) Insert the rear power outlet receptacle base
and mount into the right quarter trim panel as a
unit until the mount is seated flush against the trim
panel.
(5) Press firmly on the rear power outlet receptacle
base until the retaining bosses of the mount are fully
engaged in their receptacles.
(6) Install the protective cap into the rear power
outlet receptacle base.
(7) Reconnect the battery negative cable.
Fig. 21 Power Outlet Remove/Install - Typical
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
8W - 97 - 18 8W-97 POWER DISTRIBUTIONWJ
REAR POWER OUTLET (Continued)

NOTE: Before the engine or the transmission can
be removed the engine bending braces must be
removed.
(1) Raise and support vehicle.
NOTE: Both left and right side bending braces are
removed the sameway. Only the right side is
shown.
NOTE: The exhaust does not require removal to
preform this procedure.
(2) Remove the exhaust hanger bracket retaining
bolt.
(3) Remove locknut and transmission bending
brace bar.
(4) Remove engine-to-bending brace retaining bolt,
bending brace bar and cross bar.
INSTALLATION
NOTE: DO NOT tighten the retaining hardware until
all bending braces are in place.
(1) Position the cross brace into the engine-to-
transmission brace, then position the engine-to-trans-
mission brace and install retaining bolt.
(2) Position the transmission bending brace onto
through brace and install new locknut.
(3) Position exhaust hanger and transmission
brace, install retaining bolt (Fig. 72).
(4) Tighten engine-to-transmission brace retaining
bolt (Fig. 71)to 40 N´m (30 ft. lbs.).
(5) Tighten transmission brace retaining bolts (Fig.
72)to 40 N´m (30 ft. lbs.), then tighten transmission
brace retaining lock nuts (Fig. 72) to 108 N´m (80 ft.
lbs.).
LUBRICATION
DESCRIPTION
A gearÐtype positive displacement pump is
mounted at the underside of the block opposite the
No. 4 main bearing.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery thatchannels the oil up to the main gallery which
extends the entire length of the block.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
Fig. 71 Engine-to-Transmission Bending Braces
1 - ENGINE-TO-TRANSMISSION BENDING BRACE
2 - CROSS BRACE
3 - ENGINE-TO-TRANSMISSION BENDING BRACE RETAINING
BOLT
Fig. 72 Transmission Bending Braces and Exhaust
Hanger
1 - TRANSMISSION BENDING BRACE RETAINING BOLT
2 - ENGINE-TO-TRANSMISSION BENDING BRACE
3 - LOCKNUT
4 - TRANSMISSION BRACE
5 - EXHAUST HANGER
9 - 50 ENGINE - 4.0LWJ
STRUCTURAL SUPPORT (Continued)

(3) Install intake manifold on the cylinder head
dowels.
(4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 84).
(5) Install washer and fastener Numbers 6 and 7
(Fig. 84).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 84).
²Fastener Numbers 1 through 5ÐTighten to 33
N´m (24 ft. lbs.) torque.
²Fastener Numbers 6 and 7ÐTighten to 31 N´m
(23 ft. lbs.) torque.
²Fastener Numbers 8 through 11ÐTighten to 33
N´m (24 ft. lbs.) torque.
(7) Install the power steering pump to the intake
manifold.
(8) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the fuel system supply line to the fuel
rail assembly.
(10) Connect all electrical connections on the
intake manifold.
(11) Connect the vacuum hoses previously
removed.
(12) Install throttle cable, vehicle speed control
cable (if equipped).
(13) Install the transmission line pressure cable (if
equipped) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - AW4/THROTTLE VALVE
CABLE - INSTALLATION).
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the resonator assem-
bly.
(16) Raise the vehicle.
(17) Connect the exhaust pipes to the engine
exhaust manifolds. Tighten the bolts to 31 N´m (23
ft. lbs.)
(18) Lower the vehicle.(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust manifolds (Fig. 85) are log style
and are made of high silicon molybdenum cast iron.
The exhaust manifolds share a common gasket with
the intake manifold. The exhaust manifolds also
incorporate ball flange outlets for improved sealing
and strain free connections.
REMOVAL
The intake and engine exhaust manifolds on the
4.0L engine must be removed together. The manifolds
use a common gasket at the cylinder head.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - REMOVAL).
INSTALLATION
(1) The exhaust manifold and the intake manifold
must be installed together using a common gasket.
(2) (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - INSTALLATION).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) Remove the fan, hub assembly and fan shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL) (if equipped) and gen-
erator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 86).
INSTALLATION
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
Fig. 84 Intake and Exhaust Manifolds Installation
9 - 58 ENGINE - 4.0LWJ
INTAKE MANIFOLD (Continued)

Fig. 88 Engine Oil Lubrication System
1 - LEFT CYLINDER HEAD OIL GALLERY
2 - OIL PRESSURE SENSOR LOCATION
3 - TO LEFT CYLINDER HEAD
4 - OIL FEED TO IDLER SHAFT
5 - OIL PUMP OUTLET TO BLOCK
6 - OIL PUMP7 - TO CRANKSHAFT MAIN JOURNALS
8 - RIGHT CYLINDER HEAD OIL GALLERY
9 - TO RIGHT CYLINDER HEAD
10 - CYLINDER BLOCK MAIN GALLERY
11 - OIL FEED TO BOTH SECONDARY TENSIONERS
WJENGINE - 4.7L 9 - 127
LUBRICATION (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION - EXHAUST SYSTEM.........1
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM.............................3
SPECIFICATIONS
TORQUE.............................3
CATALYTIC CONVERTER - 4.0L
DESCRIPTION - CATALYTIC CONVERTER
4.0L ENGINE..........................4
REMOVAL.............................4
INSPECTION...........................5
INSTALLATION..........................5
CATALYTIC CONVERTER - 4.7L
DESCRIPTION - CATALYTIC CONVERTER.....6
REMOVAL.............................6
INSPECTION...........................7
INSTALLATION..........................7EXHAUST PIPE - 4.0L
REMOVAL.............................8
INSPECTION...........................8
INSTALLATION..........................8
EXHAUST PIPE - 4.7L
REMOVAL.............................10
INSPECTION..........................10
INSTALLATION.........................10
HEAT SHIELDS
DESCRIPTION.........................12
MUFFLER
DESCRIPTION.........................12
REMOVAL.............................12
INSTALLATION.........................12
TAILPIPE
DESCRIPTION.........................13
OPERATION...........................13
EXHAUST SYSTEM
DESCRIPTION - EXHAUST SYSTEM
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.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan heat shields. Light overspray near the
edges is permitted. Application of coating will result
in excessive floor pan temperatures and objection-
able fumes.
The exhaust system uses a single muffler with a
welded tailpipe.The 50 State Emissions vehicles use two mini cat-
alytic converters inline with the exhaust pipe below
the exhaust manifolds.
The exhaust manifolds are equipped with ball
flange outlets to assure a tight seal and strain free
connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it may amplify objec-
tionable noises originating from the engine or body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
The basic exhaust system consists of exhaust man-
ifold(s), exhaust pipe with oxygen sensors, catalytic
converter(s), heat shield(s), muffler and tailpipe (Fig.
1) and (Fig. 2).
WJEXHAUST SYSTEM 11 - 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

The regulator is calibrated to maintain fuel system
operating pressure of approximately 339 kPa   34
kPa (49.2 psi   5 psi) at the fuel injectors. It contains
a diaphragm, calibrated springs and a fuel return
valve. The internal fuel filter is also part of the
assembly.
Fuel is supplied to the filter/regulator by the elec-
tric fuel pump. The regulator acts as a check valve to
maintain some fuel pressure when the engine is not
operating. This will help to start the engine. A second
check valve is located at the outlet end of the electric
fuel pump.
If fuel pressure at the pressure regulator exceeds
approximately 49 psi, an internal diaphragm closes.
Excess fuel is then routed into a separate fuel return
line and returned to the fuel tank through the top of
the fuel pump module.
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.
REMOVAL
The combination Fuel Filter/Fuel Pressure Regula-
tor is remotely mounted to the vehicle body, above
the rear axle and near the front of the fuel tank (Fig.
4) or (Fig. 5).
(1) Perform Fuel System Pressure Release Proce-
dure.
(2) Disconnect negative battery cable at battery.
(3) Raise vehicle.
(4) Clean area around 3 filter/regulator fittings.
(5) Disconnect fuel supply, fuel return and fuel
pressure lines at filter/regulator (Fig. 4) . Refer to
Quick-Connect Fittings.
(6) Remove 2 mounting bolts (Fig. 5) and remove
filter/regulator.
INSTALLATION
The combination Fuel Filter/Fuel Pressure Regula-
tor is remotely mounted to the vehicle body, above
the rear axle and near the front of the fuel tank (Fig.
4) or (Fig. 5).
(1) Before installing filter/regulator, be sure all fit-
tings are cleaned of all dirt and contaminants.
(2) Be sure o-ring is positioned into fuel return fit-
ting in filter/regulator.
Fig. 3 Fuel Filter/Fuel Pressure Regulator Location
1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
Fig. 4 Fuel Filter/Fuel Pressure Regulator Location
1 - FUEL SUPPLY LINE (TO FUEL RAIL)
2 - EVAP LINE
3 - FUEL RETURN LINE (MALE)
4 - FUEL PRESSURE LINE (FEMALE)
5 - FUEL FILTER/PRESSURE REGULATOR
6 - FUEL TANK
14 - 6 FUEL DELIVERYWJ
FUEL FILTER/PRESSURE REGULATOR (Continued)