2003 JEEP GRAND CHEROKEE Workshop Manual

length wheel bolt torque engine sunroof tire pressure spare wheel

Page 1225 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual Fig. 38 LIFTGATE
Fig. 39 TRAILER TOW
8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Page 1226 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual 8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
CIGAR LIGHTER OUTLET
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
CIGAR LIGHTER OUTLET DOOR SPRING
REMOVAL.............................3
INSTALLATION..........................3
IOD FUSE
DESCRIPTION..........................3
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
JUNCTION BLOCK
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
POWER DISTRIBUTION CENTER
DESCRIPTION..........................7
OPERATION............................8
REMOVAL.............................8
DISASSEMBLY
POWER DISTRIBUTION CENTER
DISASSEMBLY........................9ASSEMBLY
POWER DISTRIBUTION CENTER
ASSEMBLY..........................11
INSTALLATION.........................12
POWER OUTLET
DESCRIPTION - FRONT POWER OUTLET....12
OPERATION - FRONT POWER OUTLET......12
DIAGNOSIS AND TESTING - POWER OUTLET . 12
REMOVAL.............................13
INSTALLATION.........................13
POWER OUTLET RELAY
DESCRIPTION.........................13
OPERATION...........................14
DIAGNOSIS AND TESTING - POWER OUTLET
RELAY..............................14
REMOVAL.............................15
INSTALLATION.........................15
IOD WIRE HARNESS CONNECTOR
DESCRIPTION.........................15
OPERATION...........................15
FUSE COVER
REMOVAL.............................16
INSTALLATION.........................16
REAR POWER OUTLET
DESCRIPTION - REAR POWER OUTLET.....16
OPERATION - REAR POWER OUTLET.......17
DIAGNOSIS AND TESTING - REAR POWER
OUTLET............................17
REMOVAL.............................17
INSTALLATION.........................18
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Power Distribution Center (PDC)
²Junction Block (JB)
²Power Outlets
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses²Circuit splice blocks
²Flashers
²Fusible links
²Standard and Micro-Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components. Refer to Wir-
ing Diagrams for complete circuit diagrams.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the standard and optional factory-in-
stalled electrical and electronic powertrain, chassis,
safety, security, comfort and convenience systems. At
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 1

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JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual the same time, the power distribution system was
designed to provide ready access to these electrical
distribution points for the vehicle technician to use
when conducting diagnosis and repair of faul

the same time, the power distribution system was
designed to provide ready access to these electrical
distribution points for the vehicle technician to use
when conducting diagnosis and repair of faulty cir-
cuits. The power distribution system can also prove
useful for the sourcing of additional electrical circuits
that may be required to provide the electrical current
needed to operate accessories that the vehicle owner
may choose to have installed in the aftermarket.
NOTE: DO NOT ATTEMPT TO SWAP POWER DIS-
TRIBUTION CENTERS FROM ONE VEHICLE TO
ANOTHER. MOST OF THESE ASSEMBLIES ARE
VEHICLE FEATURE SPECIFIC AND THEREFORE
NOT INTERCHANGEABLE. ALWAYS USE THE COR-
RECT PART NUMBERED ASSEMBLY WHEN DIAG-
NOSING OR REPLACING A POWER DISTRIBUTION
CENTER.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
A cigar lighter outlet is standard equipment on
this model. On models equipped with the optional
Smoker's Package, the cigar lighter knob and heating
element are included. On models without the Smok-
er's Package, the cigar lighter outlet is equipped with
a snap fit plastic cap and is treated as an extra
accessory power outlet. The cigar lighter outlet is
installed in the instrument panel center lower bezel,
which is located near the bottom of the instrument
panel center stack area, below the heater and air
conditioner controls. The cigar lighter outlet is
secured by a snap fit within the center lower bezel.The cigar lighter outlet, plastic cap and the knob
and heating element unit are available for service
replacement. These components cannot be repaired
and, if faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or outlet shell. The receptacle shell is
connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The cigar lighter receives battery voltage from a fuse
in the junction block when the ignition switch is in
the Accessory or On positions.
The cigar lighter knob and heating element are
encased within a spring-loaded housing, which also
features a sliding protective heat shield. When the
knob and heating element are inserted in the outlet
shell, the heating element resistor coil is grounded
through its housing to the outlet shell. If the cigar
lighter knob is pushed inward, the heat shield slides
up toward the knob exposing the heating element,
and the heating element extends from the housing
toward the insulated contact in the bottom of the
outlet shell.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the outlet shell. These clips engage and hold the
heating element against the insulated contact long
enough for the resistor coil to heat up. When the
heating element is engaged with the contact, battery
current can flow through the resistor coil to ground,
causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the outlet shell, the protective heat
shield slides downward on the housing so that the
heating element is recessed and shielded around its
circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For complete circuit diagrams, refer toHorn/Ci-
gar Lighter/Power Outletin Wiring Diagrams.
(1) Check the fused B(+) fuse in the junction block.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fused B(+) fuse in
Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTIONWJ
POWER DISTRIBUTION (Continued)

Page 1228 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual the junction block. If OK, go to Step 3. If not OK,
repair the open or short as required.
(3) Remove the cigar lighter knob and element
from the cigar lighter outlet shell. Check for continu-
ity betw

the junction block. If OK, go to Step 3. If not OK,
repair the open or short as required.
(3) Remove the cigar lighter knob and element
from the cigar lighter outlet shell. Check for continu-
ity between the inside circumference of the cigar
lighter outlet shell and a good ground. there should
be continuity. If OK, go to Step 4. If not OK, go to
Step 5.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the insulated contact
located at the back of the cigar lighter outlet shell. If
OK, replace the faulty cigar lighter knob and ele-
ment. If not OK, go to Step 5.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the instrument panel center lower bezel.
Check for continuity between the ground circuit cav-
ity of the cigar lighter 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. Turn the
ignition switch to the Accessory or On positions.
Check for battery voltage at the fused B(+) circuit
cavity of the cigar lighter wire harness connector. If
OK, replace the faulty cigar lighter outlet. If not OK,
repair the open fused B(+) circuit to the junction
block fuse as required.
CIGAR LIGHTER OUTLET
DOOR SPRING
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel center lower
bezel from the I.P. Refer to Body for the procedure.
(3) Remove the cigar lighter outlet door spring
from its locating holes (Fig. 1).
INSTALLATION
(1) Install the cigar outlet door spring in its locat-
ing holes.
(2) Install the instrument panel center lower bezel
on the I.P. Refer to Body for the procedure.
(3) Connect the negative battery cable.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse (Fig. 2) that is removed from its
cavity in the Power Distribution Center (PDC) when
the vehicle is shipped from the factory. Dealer per-sonnel are to remove the IOD fuse from the storage
location and install it into PDC fuse cavity 15 as part
Fig. 1 Cigar Lighter Outlet Door Spring
1 - CIGAR LIGHTER OUTLET
2 - CIGAR LIGHTER OUTLET DOOR SPRING
Fig. 2 Ignition-Off Draw Fuse
1 - POWER DISTRIBUTION CENTER
2 - IGNITION-OFF DRAW FUSE
3 - IOD FUSE STORAGE CAVITY
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 3
CIGAR LIGHTER OUTLET (Continued)

Page 1229 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual of the preparation procedures performed just prior to
new vehicle delivery.
The PDC has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the PDC.

of the preparation procedures performed just prior to
new vehicle delivery.
The PDC has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the PDC. An integral latch and hinges
are molded into the PDC cover for easy removal. A
fuse layout map is integral to the underside of the
PDC cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 50 ampere maxi-type car-
tridge fuse and, when removed, it is stored in a spare
fuse cavity within the PDC.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from PDC fuse cavity 15
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not toexceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
The Ignition-Off Draw (IOD) fuses normal installa-
tion location is cavity 15 in the power distribution
center. When the vehicle is shipped from the assem-
bly plant the fuse is removed to maintain proper bat-
tery voltage during vehicle storage (in some cases).
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for customer delivery in
order to restore full electrical system operation.
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the power distri-
bution center.
(3) Remove the IOD fuse from fusecavity 15of
the power distribution center (Fig. 2).
(4) Store the removed IOD fuse by installing it in
the unused fuse storagecavity 11of the PDC (Fig.
2).
(5) Close and latch the power distribution center
cover.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the power distri-
bution center.
(3) Remove the stored IOD fuse from fuse storage
cavity 11of the power distribution center.
(4) Use a thumb to press the IOD fuse firmly down
into power distribution center fusecavity 15.
(5) Close and latch the power distribution center
cover.
8W - 97 - 4 8W-97 POWER DISTRIBUTIONWJ
IOD FUSE (Continued)

Page 1230 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual JUNCTION BLOCK
DESCRIPTION
An electrical Junction Block (JB) is concealed
beneath the driver side of the instrument panel in
the passenger compartment of the vehicle (Fig. 3).
The JB combines the func

JUNCTION BLOCK
DESCRIPTION
An electrical Junction Block (JB) is concealed
beneath the driver side of the instrument panel in
the passenger compartment of the vehicle (Fig. 3).
The JB combines the functions previously provided
by a separate fuseblock module and relay center. The
JB serves to simplify and centralize numerous elec-
trical components, as well as to distribute electrical
current to many of the accessory systems in the vehi-
cle. It also eliminates the need for numerous splice
connections. The JB houses up to thirty-three blade-
type mini fuses, up to two blade-type automatic
resetting circuit breakers, the electronic combination
flasher, the Daytime Running Lamp (DRL) module
(Canada only) and up to twelve International Stan-
dards Organization (ISO) relays (three standard-type
and nine micro-type). The JB also incorporates an
integral connector and mounting for the Body Con-
trol Module (BCM). The BCM is secured with four
screws directly to the dash panel side of the JB.
Refer toBody Control Modulein Electronic Con-
trol Modules for additional information covering the
BCM.
The molded plastic JB housing has integral mounts
that are secured with two screws and two snap
retainers to the instrument panel steering column
support bracket behind the instrument panel steer-ing column opening cover. The JB is concealed above
the molded plastic instrument panel fuse cover. Inte-
gral latches molded into the fuse cover secure it the
JB, the BCM and the 16-way data link connector tab
of the instrument panel steering column support
bracket. The fuse cover can be pulled downward to
disengage the latches and provide service access to
all of the fuses, relays and wire harness connectors of
the JB. The fuse cover has a fuse puller and spare
fuses secured to its upper surface. Refer toInstru-
ment Panel Fuse Coverin Body for additional ser-
vice information.
The JB unit cannot be repaired and is only ser-
viced as an assembly. If any internal circuit or the JB
housing is faulty or damaged, the entire JB unit
must be replaced. The BCM is available for separate
service replacement.
OPERATION
All of the circuits entering and leaving the Junc-
tion Block (JB) do so through up to five wire harness
connectors, which are connected to the JB through
integral connector receptacles molded into the JB
housing. Internal connection of all of the JB circuits
is accomplished by a printed circuit board. There are
also two separate wire harness connections to con-
nector receptacles that are integral to the BCM.
Refer toJunction Blockin Wiring Diagrams for
additional information and the location of complete
JB circuit diagrams.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the fuse cover from the bottom of the
Junction Block (JB).
(3) Remove the steering column opening cover
from the instrument panel. Refer toSteering Col-
umn Opening Coverin Body for the location of
steering column opening cover removal procedures.
Fig. 3 Junction Block Location
1 - REAR LATCHES
2 - JUNCTION BLOCK AND BODY CONTROL MODULE UNIT
3 - INSTRUMENT PANEL FUSE COVER
4 - SIDE LATCH
5 - FRONT LATCHES
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 5

Page 1231 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (4) Reach behind the JB to disconnect the two
instrument panel wire harness connectors from the
Body Control Module (BCM) connector receptacles
located near the bottom of the JB (Fig. 4).
(5) Reach be

(4) Reach behind the JB to disconnect the two
instrument panel wire harness connectors from the
Body Control Module (BCM) connector receptacles
located near the bottom of the JB (Fig. 4).
(5) Reach behind the JB to remove the screw that
secures the instrument panel wire harness bulkhead
connector to the connector receptacle located near the
top of the JB and disconnect the connector.
(6) Disconnect the fused B(+) and the IOD wire
harness connectors from the connector receptacles
located near the bottom of the JB (Fig. 5).
(7) Remove the screws that secure the right and
left body wire harness bulkhead connectors to the
connector receptacles located near the center of the
JB and disconnect the connectors.
(8) Remove the two screws that secure the JB to
the instrument panel steering column support
bracket (Fig. 6).
(9) To disengage the two snap clips that secure the
top of the JB to the instrument panel steering col-
umn support bracket, grasp the bottom of the junc-
tion block firmly with both hands and pull it
downward sharply.
(10) Remove the JB from the instrument panel
steering column support bracket.
INSTALLATION
NOTE: If the Junction Block (JB) is being replaced
with a new unit, be certain to transfer each of the
optional fuses, circuit breakers and relays from thefaulty JB to the proper cavities of the replacement
JB. Refer to Junction Block in Wiring Diagrams for
the location of complete circuit diagrams and cavity
assignments for the JB. The Body Control Module
(BCM) must also be transferred to the new JB.
Refer to Body Control Module in Electronic Control
Modules for the location of the BCM removal and
installation procedures.
(1)
Position the JB into its mounting location on the
instrument panel steering column support bracket.
(2) Align the snap clips at the top of the JB with
the mounting holes in the instrument panel steering
column support bracket.
(3) Grasp the bottom of the JB firmly with both
hands and push it upward sharply to engage the two
snap clips that secure the top of the JB to the instru-
ment panel steering column support bracket.
(4)
Install and tighten the two screws that secure the
JB to the instrument panel steering column support
bracket. Tighten the screws to 2.2 N´m (20 in. lbs.).
Fig. 4 Junction Block Connections
1 - SCREW
2 - JUNCTION BLOCK
3 - BULKHEAD CONNECTOR
4 - BODY CONTROL MODULE
5 - INSTRUMENT PANEL WIRE HARNESS CONNECTORS
Fig. 5 Junction Block Connections
1 - SNAP CLIPS
2 - SCREW
3 - CONNECTOR
4 - LEFT BODY WIRE HARNESS
5 - IOD CONNECTOR
6 - FUSED B+ CONNECTOR
7 - RIGHT BODY WIRE HARNESS
8 - SCREW
9 - CONNECTOR
10 - JUNCTION BLOCK
8W - 97 - 6 8W-97 POWER DISTRIBUTIONWJ
JUNCTION BLOCK (Continued)

Page 1232 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (5) Reconnect the right and left body wire harness
bulkhead connectors to the connector receptacles
located near the center of the JB.
(6) Install and tighten the screws that secure the
right and left

(5) Reconnect the right and left body wire harness
bulkhead connectors to the connector receptacles
located near the center of the JB.
(6) Install and tighten the screws that secure the
right and left body wire harness bulkhead connectors
to the connector receptacles located near the center
of the JB. Tighten the screws to 2.2 N´m (20 in. lbs.).
(7) Reconnect the fused B(+) and the IOD wire
harness connectors to the connector receptacles
located near the bottom of the JB.
(8) Reach behind the JB to reconnect the instru-
ment panel wire harness bulkhead connector to the
connector receptacle located near the top of the JB.
(9) Install and tighten the screw that secures the
instrument panel wire harness bulkhead connector to
the connector receptacle located near the top of the
JB. Tighten the screw to 2.2 N´m (20 in. lbs.).
(10)
Reach behind the JB to reconnect the two
instrument panel wire harness connectors to the BCM
connector receptacles located near the bottom of the JB.
(11) Install the steering column opening cover onto
the instrument panel. Refer toSteering Column
Opening Coverin Body for the location of the steer-
ing column opening cover installation procedures.
(12)
Install the fuse cover onto the bottom of the JB.
(13) Reconnect the battery negative cable.
POWER DISTRIBUTION
CENTER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the standard equip-ment Power Distribution Center (PDC) (Fig. 7). The
molded plastic PDC housing is located in the right
front corner of the engine compartment, between the
battery and the right front inner fender shield. The
PDC houses up to fifteen maxi-type cartridge fuses,
which replace all in-line fusible links. The PDC also
houses up to thirteen blade-type mini fuses, and up
to ten International Standards Organization (ISO)
relays (two standard-type and eight micro-type).
The PDC housing is secured in the engine compart-
ment at three points. Integral mounts on both sides of
the PDC housing engage and latch to stanchions that
are integral to the molded plastic battery support. The
PDC is integral to the right headlamp and dash wire
harness, which exits from the bottom of the PDC hous-
ing. The PDC housing has a molded plastic cover that
includes two integral latches at the front and pivot
hooks at the back that snap over a hinge pin on the
rear of the PDC housing. The PDC cover is easily
opened or removed for service access and has a conve-
nient fuse and relay layout map integral to the inside
surface of the cover to ensure proper component identi-
fication. A fuse puller is also stored on the inside of the
PDC cover.
The PDC cover, the PDC housing lower cover, the
PDC relay wedges, the PDC relay cassettes and the
PDC B(+) terminal stud module are available for ser-
vice replacement. The PDC main housing unit, the
fuse wedges and the bus bars cannot be repaired and
Fig. 6 Junction Block
1 - SCREW (2)
2 - DRIVER SIDE COURTESY LAMP
3 - JUNCTION BLOCK
4 - 16 WAY DATA LINK CONNECTOR
Fig. 7 Power Distribution Center Location
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
WJ8W-97 POWER DISTRIBUTION 8W - 97 - 7
JUNCTION BLOCK (Continued)

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