2003 JEEP GRAND CHEROKEE Workshop Manual

flat tire power steering fluid roof bonnet recommended oil bolt pattern

Page 1409 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual HEAT SHIELDS
DESCRIPTION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed by the catalytic converter. The catalytic
converter releases addit

HEAT SHIELDS
DESCRIPTION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed by the catalytic converter. The catalytic
converter releases additional heat into the exhaust
system. Under severe operating conditions, the tem-
perature increases in the area of the converter. Such
conditions can exist when the engine misfires or oth-
erwise does not operate at peak efficiency (Fig. 17).
MUFFLER
DESCRIPTION
Both the 4.0L and 4.7L engines use a stainless
steel muffler to control exhaust noise levels and
exhaust back pressure. The muffler and tailpipe are
a one piece assembly (Fig. 18).
REMOVAL
All original equipment exhaust systems are manu-
factured with the tailpipe welded to the muffler. Ser-
vice replacement mufflers and tailpipes are either
clamped together or welded together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.(3) Loosen the exhaust clamp on the catalytic con-
verter to muffler connection (Fig. 19).
(4) Heat the catalytic converter-to-muffler connec-
tion with a torch until the metal becomes cherry red.
(5) While the metal is still cherry red, remove the
tailpipe/muffler assembly from the catalytic con-
verter.
(6) Remove the tailpipe from the tailpipe hanger
(Fig. 20).
(7) Remove the tailpipe/muffler assembly (Fig. 20).
INSTALLATION
(1) If the tailpipe hanger assembly was removed,
install the hanger to the frame. Tighten the bolts to
22 N´m (192 in. lbs.) torque.
(2) Position the tailpipe and muffler onto the
tailpipe hanger (Fig. 20) .
(3) Install the muffler onto the catalytic converter.
Make sure that the tailpipe has sufficient clearance
from the floor pan. Install exhaust clamp and tighten
the nuts to 47 N´m (35 ft. lbs.) torque (Fig. 19) .
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
Fig. 17 Front and Rear Floor Pan Heat Shields
Typical
1 - REAR FLOOR PAN HEAT SHIELD
2 - HEAT SHIELD RETAINING NUTS (QTY 8)
3 - FRONT FLOOR PAN HEAT SHIELD
Fig. 18 Muffler and Tailpipe
1 - CATALYTIC CONVERTER
2 - TAILPIPE HANGER
3 - TAILPIPE
4 - MUFFLER
11 - 12 EXHAUST SYSTEMWJ

Page 1410 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual TAILPIPE
DESCRIPTION
The tailpipe is also made of stainless steel. (Fig.
18) .
OPERATION
The Tailpipe channels the exhaust out of the muf-
fler and out from under the vehicle to control noise
and prev

Page 1411 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

Page 1412 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT ABSORBER
REMOVAL.............................1
INSTALLATION..........................1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT ABSORBER
REMOVAL.............................1
INSTALLATION..........................1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
REAR ABSORBER
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................4
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE.............4
FRAME DIMENSIONS...................4
FRONT SKID PLATE
REMOVAL.............................7INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
FUEL TANK SKID PLATE
DESCRIPTION..........................7
REAR TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
TRAILER HITCH
REMOVAL.............................8
INSTALLATION..........................8
TRANSFER CASE SKID PLATE
REMOVAL.............................8
INSTALLATION..........................8
FRONT ABSORBER
REMOVAL
(1) Remove front fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL).
(2) Remove the retainer attaching the absorber to
the fascia.
(3) Separate the absorber from the fascia.
INSTALLATION
(1) Position the absorber on the fascia.
(2) Install the retainer attaching the absorber to
the fascia.
(3) Install front fascia. Refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
FRONT FASCIA
REMOVAL
(1) Raise and support vehicle.
(2) Turn front wheels to access rivets and remove
plastic rivets attaching fascia to wheel liner.
(3) Remove bolts attaching fascia to fender (Fig. 1).(4) Remove plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(5) Disengage fog lamp connectors, if equipped.
(6) Remove screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(7) Slide fascia forward to separate from vehicle.
INSTALLATION
(1) Slide fascia onto vehicle engaging fascia with
tabs on bottom of front fenders.
(2) Install screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(3) Install bolts attaching fascia to fender (Fig. 1).
(4) Engage fog lamp connectors, if equipped.
(5) Install plastic rivets attaching fascia to wheel
liner.
(6) Install plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(7) Remove supports and lower vehicle.
WJFRAME & BUMPERS 13 - 1

Page 1413 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual REAR ABSORBER
REMOVAL
(1) Remove rear fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL).
(2) Remove rivets attaching absorber to rear cross-
member (Fig. 5).
(3) Separate

Page 1414 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (5) Remove nuts attaching upper edge of fascia to
quarter panel and wheel liner (Fig. 4).
(6) Remove plastic push pins attaching fascia to
liftgate opening (Fig. 5).
(7) Remove screws attaching fascia

Page 1415 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual INSTALLATION
(1) Position fascia on vehicle aligning retainers
with slots in quarter panel (Fig. 7).
(2) Press forward edges of fascia inward to engage
retainers.
(3) Install screws attaching fascia t

Page 1416 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual Fig. 8 SIDE VIEW
WJFRAME & BUMPERS 13 - 5
FRAME (Continued)

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