2002 JEEP GRAND CHEROKEE weatherstrip

(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Disconnect generator electrical connections.
(8) Unbolt the generator and move it away from
the intake manifold for clearance.
(9) Disconnect air conditioning compressor electri-
cal connections.
(10) Unbolt the air conditioning compressor and
move it away from the intake manifold for clearance.
(11) Disconnect left and right radio suppressor
straps.
(12) Disconnect and remove ignition coil towers
(Refer to 8 - ELECTRICAL/IGNITION CONTROL/
IGNITION COIL - REMOVAL).
(13) Remove top oil dipstick tube retaining bolt
and ground strap.
(14) Bleed pressure from fuel system (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(15) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(16) Remove throttle body assembly and mounting
bracket.
(17) Drain cooling system below coolant tempera-
ture level (Refer to 7 - COOLING - STANDARD
PROCEDURE).
(18) Remove coolant temperature sensor (Refer to
7 - COOLING/ENGINE/ENGINE COOLANT TEMP
SENSOR - REMOVAL).
(19) Remove cowl to hood seal. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/COWL WEATHER-
STRIP - REMOVAL).
(20) Remove right side engine lifting stud.
(21) Remove intake manifold retaining fasteners,
in reverse order of tightening sequence (Fig. 105).
NOTE: Intake must be lifted upward and level in the
front and rear to clear the cowl. Interference with
the cowl will occur during removal.
(22) Remove intake manifold.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before installing the intake manifold thoroughly
clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
(1) Install intake manifold gaskets.
(2) Install intake manifold.
(3) Install intake manifold retaining bolts and
tighten in sequence shown in (Fig. 106) to 12 N´m
(105 in. lbs.).
(4) Install left and right radio suppressor straps.
(5) Install throttle body assembly.
(6) Install throttle cable bracket.
Fig. 105 Intake Manifold Tightening Sequence
Fig. 106 Intake Manifold Tightening Sequence
WJENGINE - 4.7L 9 - 137
INTAKE MANIFOLD (Continued)

(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(9) Install ignition coil towers (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/IGNITION COIL -
INSTALLATION).
(10) Install coolant temperature sensor (Refer to 7
- COOLING/ENGINE/ENGINE COOLANT TEMP
SENSOR - INSTALLATION).
(11) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(12) Install top oil dipstick tube retaining bolt and
ground strap.
(13) Install right side engine lifting stud.
(14) Install generator including electrical connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - INSTALLATION).
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Install air conditioning compressor including
electrical connections.
(17) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(18) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(19) Install cowl to hood seal (Refer to 23 - BODY/
WEATHERSTRIP/SEALS/COWL WEATHERSTRIP -
INSTALLATION).
(20) Install air cleaner housing and throttle body
resonator. Tighten resonator bolts 4.5 N´m (40 in.
lbs.).
(21) Connect negative cable to battery.
EXHAUST MANIFOLD - LEFT
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nutthat is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
(1) Disconnect negative cable for battery.
(2) Hoist vehicle.
(3) Disconnect exhaust pipe at manifold.
(4) Lower vehicle.
(5) Remove air cleaner housing and tube.
(6) Remove the front two exhaust heat shield
retaining fasteners. Raise vehicle and remove the
fasteners at rear of heat shield.
(7) Remove heat shield (Fig. 107).
(8) Lower vehicle and remove the upper exhaust
manifold retaining bolts (Fig. 107).
(9) Raise vehicle and remove the lower exhaust
manifold retaining bolts (Fig. 107).
(10) Remove exhaust manifold and gasket (Fig.
107). Manifold is removed from below the engine
compartment.
CLEANING
(1) Clean the exhaust manifold using a suitable
cleaning solvent, then allow to air dry.
(2) Clean all gasket residue from the manifold
mating surface.
INSPECTION
(1) Inspect the exhaust manifold for cracks in the
mating surface and at every mounting bolt hole.
(2) Using a straight edge and a feeler gauge, check
the mating surface for warp and twist.
(3) Inspect the manifold to exhaust pipe mating
surface for cracks, gouges, or other damage that
would prevent sealing.
INSTALLATION
(1) Install exhaust manifold and gasket from below
engine compartment.
(2) Install lower exhaust manifold fasteners (Fig.
107). DO NOT tighten until all fasteners are in
place.
(3) Lower vehicle and install upper exhaust mani-
fold fasteners (Fig. 107). Tighten all manifold bolts
starting at center and working outward to 25 N´m
(18 ft. lbs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) Install exhaust manifold heat shield (Fig. 107).
Tighten fasteners to 8 N´m (72 in. lbs.), then loosen
45 degrees.
(5) Install air cleaner housing and tube.
(6) Connect exhaust pipe to manifold.
(7) Connect negative cable to battery.
9 - 138 ENGINE - 4.7LWJ
INTAKE MANIFOLD (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DIAGNOSIS AND TESTING
WATER LEAKS........................1
WIND NOISE..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................2
STANDARD PROCEDURE - DRILLING AND
WELDING............................3
SPECIFICATIONS
BODY LUBRICANTS....................3
SPECIFICATIONS - TORQUE.............4
SPECIAL TOOLS
BODY...............................4DECKLID/HATCH/LIFTGATE/TAILGATE........5
DOOR - FRONT.........................11
DOORS - REAR.........................19
EXTERIOR.............................25
HOOD.................................33
INSTRUMENT PANEL SYSTEM.............36
INTERIOR..............................69
PAINT.................................81
SEATS................................83
STATIONARY GLASS.....................93
SUNROOF.............................96
WEATHERSTRIP/SEALS..................105
BODY STRUCTURE.....................112
BODY
DIAGNOSIS AND TESTING
WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
WJBODY 23 - 1

leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will notalways seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
23 - 2 BODYWJ
BODY (Continued)

DOOR
REMOVAL
(1) Disconnect front door harness connector (Fig.
2).
(2) Support door with padded floor jack.
(3) Remove retaining clips from hinge pins.
(4) Tap out hinge pins.
(5) Separate door from vehicle.
INSTALLATION
(1) Position door at vehicle and align hinges.
(2) Install hinge pins.
(3) Install retaining clips for hinge pins.
(4) Connect front door harness connector (Fig. 2).
ADJUSTMENTS
DOOR ADJUSTMENT
Minor adjustment for alignment of the door is
made by moving the latch striker.
IN AND OUT
(1) Loosen the latch striker.
(2) Tap the latch striker inward if the door charac-
ter line is outboard of the body character line or tap
the latch striker outward if the door character line is
inboard of the body character line.
(3) Inspect the alignment. If correct, tighten
striker to 28 N´m (21 ft. lbs.).
UP AND DOWN
(1) Loosen the latch striker.
(2) Tap the latch striker downward if the door
character line is higher than the body character lineor tap the latch striker upward if the door character
line is lower than the body character line.
(3) Inspect the alignment. If correct, tighten to 28
N´m (21 ft. lbs.).
DOOR GLASS
REMOVAL
(1) Locate glass to full down position.
(2) Remove the waterdam, refer to (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(3) Remove inner belt weatherstrip, refer to (Refer
to 23 - BODY/WEATHERSTRIP/SEALS/FDR INNER
BELT WEATHERSTRIP - REMOVAL).
(4) Remove outer belt weatherstrip, refer to (Refer
to 23 - BODY/WEATHERSTRIP/SEALS/FDR OUTER
BELT WEATHERSTRIP - REMOVAL).
(5) Locate glass to 3/4 up position.
(6) Using a long flat blade or hook type tool, dis-
engage clips (Fig. 3) attaching glass retainer to glass
lift plate.
(7) Carefully push bottom of glass panel outward
to disengage glass retainer studs from lift plate (Fig.
4).
(8) Lift glass upward and out of door.
INSTALLATION
(1) Lower glass into position.
(2) Carefully align glass retainer studs with lift
plate and insert studs into lift plate.
Fig. 2 Front Door Harness Connector
1 - HARNESS CONNECTOR
2 - DOOR
Fig. 3 Front Door Glass Clips
1 - GLASS
2 - RETAINER
3 - CLIP
4 - LIFT PLATE
5 - REGULATOR
6 - CLIP
23 - 12 DOOR - FRONTWJ

(3) Engage clips attaching glass retainer to glass
lift plate.
(4) Locate glass to full down position.
(5) Install outer belt weatherstrip, (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
WEATHERSTRIP - INSTALLATION).
(6) Install inner belt weatherstrip, (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION).
(7) Install waterdam, refer to (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
EXTERIOR HANDLE
REMOVAL
(1) Remove glass run channel, refer to (Refer to 23
- BODY/DOOR - FRONT/GLASS RUN CHANNEL -
REMOVAL).
(2) Disconnect lock cylinder to latch rod.
(3) Disconnect outside handle to latch rod
(4) Remove fasteners attaching outside handle to
door (Fig. 5).
(5) Remove outside handle from door.
(6) Disconnect anti-theft harness connector, if
equipped.
(7) Separate outside handle from vehicle.
INSTALLATION
(1) Position outside handle at door (Fig. 5).
(2) Connect anti-theft harness connector, if
equipped.
(3) Position outside handle in door.(4) Install fasteners attaching outside handle to
door.
(5) Connect outside handle to latch rod
(6) Connect lock cylinder to latch rod.
(7) Install glass run channel, refer to (Refer to 23 -
BODY/DOOR - FRONT/GLASS RUN CHANNEL -
INSTALLATION).
GLASS RUN CHANNEL
REMOVAL
NOTE: Only the rearward glass run channel is ser-
viceable.
(1) Remove the waterdam, refer to (Refer to 23 -
BODY/DOOR - FRONT/WATERDAM - REMOVAL).
(2) Remove inner belt weatherstrip, refer to (Refer
to 23 - BODY/WEATHERSTRIP/SEALS/FDR INNER
BELT WEATHERSTRIP - REMOVAL).
(3) Remove outer belt weatherstrip, refer to (Refer
to 23 - BODY/WEATHERSTRIP/SEALS/FDR OUTER
BELT WEATHERSTRIP - REMOVAL).
(4) Remove bolt attaching run channel to inner
door panel (Fig. 6).
(5) Peel back glass run channel weatherstrip on
rear run channel.
(6) Pull glass run channel downward to separate
from door.
Fig. 4 Front Door Glass Retainer
1 - GLASS
2 - RETAINER
3 - LIFT PLATE
4 - STUD
Fig. 5 Front Door Outside Handle
1 - DOOR
2 - OUTSIDE HANDLE
WJDOOR - FRONT 23 - 13
DOOR GLASS (Continued)

(7) Remove glass run channel from door.
INSTALLATION
(1) Position glass run channel in door (Fig. 6).
(2) Align glass run channel with door frame run
channel and slide channel upward to secure door.
(3) Press glass run channel weatherstrip into rear
run channel.
(4) Install bolt attaching run channel to inner door
panel.
(5) Install outer belt weatherstrip, (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR OUTER BELT
WEATHERSTRIP - INSTALLATION).
(6) Install inner belt weatherstrip, (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION).
(7) Install the waterdam, (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION).
HINGE
REMOVAL
(1) Open and support door.
(2) Using a wax pencil, or other suitable device,
reference mark the hinge placement
(3) Disconnect the door wire harness.
(4) Remove the door check from the ªAº pillar (Fig.
7).
(5) Remove the fasteners retaining the door hinge
to the door (Fig. 8).
(6) Remove the door.
(7) Remove the hinge from the ªAº pillar.
Fig. 6 Front Door Glass Run Channel
1 - DOOR
2 - GLASS
3 - GLASS RUN CHANNEL
4 - REGULATOR
Fig. 7 Front Door Check
1 - DOOR CHECK
2 - FRONT DOOR
Fig. 8 Front Door Hinges
1 - WASHER
2 - UPPER HINGE
3 - FRONT DOOR
4 - LOWER HINGE
5 - WASHER
23 - 14 DOOR - FRONTWJ
GLASS RUN CHANNEL (Continued)

DOOR
REMOVAL
(1) Disconnect rear door harness connector (Fig. 2).
(2) Support door with padded floor jack.
(3) Remove retaining clips from hinge pins.
(4) Tap out hinge pins.
(5) Separate door from vehicle.
INSTALLATION
(1) Position door at vehicle and align hinges.
(2) Install hinge pins.
(3) Install retaining clips for hinge pins.
(4) Connect rear door harness connector (Fig. 2).
DOOR GLASS
REMOVAL
(1) Remove waterdam, refer to (Refer to 23 -
BODY/DOORS - REAR/WATERDAM - REMOVAL).
(2) Remove inner belt weatherstrip, refer to (Refer
to 23 - BODY/WEATHERSTRIP/SEALS/RDR INNER
BELT WEATHERSTRIP - REMOVAL).
(3) Remove stationary glass, refer to (Refer to 23 -
BODY/STATIONARY GLASS/DOOR GLASS -
REMOVAL).
(4) Disengage clips attaching window glass to lift
plate.
(5) Press studs out of lift plate.
(6) Lift window glass from door (Fig. 3).
INSTALLATION
(1) Position window glass in door (Fig. 3).
(2) Engage studs into lift plate.
(3) Engage clips attaching window glass to lift
plate.
(4) Install stationary glass, refer to (Refer to 23 -
BODY/STATIONARY GLASS/DOOR GLASS -
INSTALLATION).
(5) Install inner belt weatherstrip, refer to (Refer
to 23 - BODY/WEATHERSTRIP/SEALS/RDR INNER
BELT WEATHERSTRIP - INSTALLATION).
(6) Install waterdam, refer to (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION).
EXTERIOR HANDLE
REMOVAL
(1) Remove waterdam, refer to (Refer to 23 -
BODY/DOORS - REAR/WATERDAM - REMOVAL).
(2) Locate glass to full up position.
(3) Disconnect lock knob to latch rod.
(4) Disconnect outside handle to latch rod.
(5) Remove fasteners attaching outside handle to
door (Fig. 4).
(6) Remove outside handle from door.
(7) Separate outside handle from vehicle.
Fig. 2 Rear Door Harness Connector
1 - HARNESS CONNECTOR
Fig. 3 Glass Channel
1 - GLASS
2 - REGULATOR
23 - 20 DOORS - REARWJ