2003 JEEP GRAND CHEROKEE Bumper

INSTALLATION
(1) Position relay to body and install 2 bolts.
Tighten bolts to 3 N´m (25 in. lbs.) torque.
(2) Connect electrical connector to relay.
(3) Connect vacuum hose to reservoir.
(4) Install reservoir and tighten 2 bolts to 3 N´m
(25 in. lbs.) torque.
(5) Install front bumper and grill assembly.
RADIATOR - 4.7L
DESCRIPTION
All vehicles are equipped with a cross flow type
radiator with plastic side tanks (Fig. 31).
Plastic tanks, while stronger than brass, are sub-
ject to damage by impact, such as from tools or
wrenches. Handle radiator with care.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 32). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 33). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 34). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Disconnect the negative battery cable at bat-
tery.
(2) Drain coolant from radiator (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(3) Remove the front grill (Refer to 23 - BODY/EX-
TERIOR/GRILLE - REMOVAL).
Fig. 30 Radiator Cooling Fan Relay Removal/
Installation
1 - ELECTRICAL CONNECTOR
2 - RADIATOR FAN RELAY
3 - MOUNTING BOLTS (2)
Fig. 31 Cross Flow Radiator - Typical
1 - RADIATOR
7 - 42 ENGINEWJ
PWM FAN CONTROL MODULE - 4.0L (Continued)

(from rear of vehicle forward) to verify accuracy of
the line placement.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the centerline of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam will project the top
edge of the beam intensity pattern on the screen
from 25 mm (1 in.) above to 75 mm (3 in.) below
headlamp centerline. The side-to-side left edge of the
beam intensity pattern should be from 50 mm (2 in.)
left to 50 mm (2 in.) right of headlamp centerline
(Fig. 17).
(1) Clean front of the headlamps.
(2) Place headlamps on LOW beam.(3) Cover front of the headlamp that is not being
adjusted.
(4) Turn adjustment screw (Fig. 18) and (Fig. 19)
until the top edge of the beam intensity pattern is
positioned within 25 mm (1 in.) above or 75 mm (3
in.) below the headlamp horizontal centerline.
(5) Cover front of the headlamp and adjust the
other headlamp beam as instructed below.
(6) Rotate the adjustment screw until the top edge
of the beam intensity pattern is positioned within 25
mm (1 in.) above or 75 mm (3 in.) below the head-
lamp horizontal centerline.
LICENSE PLATE LAMP
REMOVAL
REMOVAL - BULB
(1) Remove lamp assembly from liftgate lamp mod-
ule.
(2) Rotate bulb socket counterclockwise to discon-
nect bulb socket from lamp.
(3) Remove bulb from socket.
Fig. 16 Headlamp Alignment ScreenÐTypical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET)4 - FRONT OF HEADLAMP
5 - VEHICLE CENTERLINE
WJLAMPS/LIGHTING - EXTERIOR 8L - 17
HEADLAMP UNIT (Continued)

(4) Install airbag module. Refer to Group 8M, Pas-
sive Restraint Systems.
(5) Connect negative battery cable.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is a plastic storage tank con-
nected to an engine vacuum source by vacuum lines.
OPERATION
The vacuum reservoir is used to supply the vac-
uum needed to maintain proper speed control opera-
tion when engine vacuum drops, such as in climbing
a grade while driving. A one-way check valve is used
in the vacuum line between the reservoir and the
vacuum source. This check valve is used to trap
engine vacuum in the reservoir. On certain vehicle
applications, this reservoir is shared with the heat-
ing/air-conditioning system. The vacuum reservoir
cannot be repaired and must be replaced if faulty.
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR
(1) Disconnect vacuum hose at speed control servo
and install a vacuum gauge into the disconnected
hose.
(2) Start engine and observe gauge at idle. Vac-
uum gauge should read at least ten inches of mer-
cury.
(3) If vacuum is less than ten inches of mercury,
determine source of leak. Check vacuum line to
engine for leaks. Also check actual engine intake
manifold vacuum. If manifold vacuum does not meet
this requirement, check for poor engine performance
and repair as necessary.
(4) If vacuum line to engine is not leaking, check
for leak at vacuum reservoir. To locate and gain
access to reservoir, refer to Vacuum Reservoir Remov-
al/Installation in this group. Disconnect vacuum line
at reservoir and connect a hand-operated vacuum
pump to reservoir fitting. Apply vacuum. Reservoir
vacuum should not bleed off. If vacuum is being lost,
replace reservoir.
(5) Verify operation of one-way check valve and
check it for leaks.
(a) Locate one-way check valve. The valve is
located in vacuum line between vacuum reservoir
and engine vacuum source. Disconnect vacuum
hoses (lines) at each end of valve.
(b) Connect a hand-operated vacuum pump to
reservoir end of check valve. Apply vacuum. Vac-
uum should not bleed off. If vacuum is being lost,
replace one-way check valve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check valve. Apply vacuum.
Vacuum should flow through valve. If vacuum is
not flowing, replace one-way check valve. Seal the
fitting at opposite end of valve with a finger and
apply vacuum. If vacuum will not hold, diaphragm
within check valve has ruptured. Replace valve.
REMOVAL
The vacuum reservoir is located in the right/front
corner of the vehicle behind the front bumper fascia
(Fig. 8).
(1) Remove front bumper and grill assembly.
(2) Remove 1 support bolt near front of reservoir
(Fig. 8).
(3) Remove 2 reservoir mounting bolts.
(4) Remove reservoir from vehicle to gain access to
vacuum hose (Fig. 9). Disconnect vacuum hose from
reservoir fitting at rear of reservoir.
Fig. 7 Speed Control Switches
1 - MOUNTING SCREW
2 - SPEED CONTROL SWITCHES
8P - 8 SPEED CONTROLWJ
SWITCH (Continued)

INSTALLATION
The vacuum reservoir is located in the right/front
corner of the vehicle behind the front bumper fascia
(Fig. 8).
(1) Connect vacuum hose to reservoir.
(2) Install reservoir and tighten 2 bolts to 3 N´m
(25 in. lbs.) torque.
(3) Install front bumper and grill assembly.
Fig. 8 Vacuum Reservoir Location
1 - RADIATOR FAN RELAY
2 - VACUUM RESERVOIR
3 - BOLT
4 - RIGHT FRONT FENDER
Fig. 9 Vacuum Reservoir Removal/Installation
1 - VACUUM HOSE
2 - RADIATOR
3 - VACUUM RESERVOIR
WJSPEED CONTROL 8P - 9
VACUUM RESERVOIR (Continued)

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
Trailer Tow Left Turn Relay BK Left Quarter Panel N/S
Trailer Tow Right Turn Relay BK Left Quarter Panel N/S
Transfer Case Position Sensor BK On Transfer Case 7
Transmission Control Module
(4.7L)BK Rear of Engine Compartment 14, 15, 18
Transmission Control Module
C1 (Diesel)BK Right Rear Side of Engine
CompartmentN/S
Transmission Control Module
C2 (Diesel)BK Right Rear Side of Engine
Compartment8
Transmission Solenoid (4.0L
Gas)BK Left Side of Transmission 12
Transmission Solenoid
Assembly (Diesel)BK On Transmission 8
Transmission Solenoid/TRS
Assembly (4.7L)GY Left Side of Transmission 16
Underhood Lamp BK At Lamp 6
Vehicle Information Center BK In Overhead Console N/S
Viscous/Cabin Heater (Diesel) BK Left Rear of Engine Compartment N/S
Washer Fluid Level Switch GY Left Front of Engine Compartment 3, 4
Wastegate Solenoid (Diesel) Near Power Distribution Center N/S
Water In Fuel Sensor (Diesel) BK Left Rear of Engine Compartment N/S
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 (4.0L and Diesel) Near Starter N/S
G100 (4.7L) Near Intake Plenum N/S
G101 Near Battery 2
G102 Right Side of Engine 14, 15
G103 Right Side of Engine 7, 8, 10, 11, 14, 15
G104 (4.0L) Right Rear of Engine 10, 11
G104 (4.7L) Left Side of Engine 13
G105 Right Side of Engine 8
G106 Left Side of Engine Compartment 3, 4
G107 Left Side of Engine Compartment 3, 4
G108 Near Power Distribution Center 5
G200 Near Airbag Control Module 19, 20, 21, 22
G201 Near Airbag Control Module 19, 20, 21, 22
G300 Near Right Front Seat 34, 36
G301 Near Left Front Seat 33, 35
WJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

REMOVAL
REMOVAL - CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled,
babbitt-lined bearings that are pressed into the cyl-
inder block and then line reamed. The camshaft
bearing bores and bearing diameters are not the
same size. They are stepped down in 0.254 mm
(0.010 inch) increments from the front bearing (larg-
est) to the rear bearing (smallest). This permits eas-
ier removal and installation of the camshaft. The
camshaft bearings are pressure lubricated. Camshaft
end play is maintained by the thrust plate.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Using Special tool 8544 Camshaft Bushing
Remover Installer, remove the camshaft bearings.
REMOVAL - CAMSHAFT
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Disconnect negative cable from battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL) and condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL), if
equipped with A/C.
(4) Remove the engine cylinder head cover (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(5) Remove the rocker arms, bridges and pivots
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL).
(6) Remove the push rods.
(7) Remove the engine cylinder head and gasket
(Refer to 9 - ENGINE/CYLINDER HEAD - REMOV-
AL).
(8) Remove the hydraulic valve tappets from the
engine cylinder block (Refer to 9 - ENGINE/ENGINE
BLOCK/HYDRAULIC LIFTERS (CAM IN BLOCK) -
REMOVAL).
(9) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(10) Remove the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Rotate the crankshaft until the crankshaft
sprocket timing mark is aligned on centerline with
the camshaft sprocket timing mark (Fig. 32).
(12) Remove the timing chain and sprockets (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - REMOVAL).
(13) Remove the front bumper and/or grille, as
required.
(14) Remove the two thrust plate retaining screws,
thrust plate and camshaft (Fig. 31).
INSPECTION
INSPECTION - CAMSHAFT BEARINGS
(1) Inspect the bearing journals for uneven wear
pattern or finish.
(2) Inspect the bearings for wear.
INSPECTION - CAMSHAFT
(1) Inspect the cam lobes for wear.
(2) Inspect the camshaft position sensor drive gear
for wear.
(3) If the camshaft appears to have been rubbing
against the thrust washer, examine the oil pressure
Fig. 30 CamshaftÐTypical
1 - CAMSHAFT
2 - LOBES
3 - BEARING JOURNAL
WJENGINE - 4.0L 9 - 31
CAMSHAFT & BEARINGS (Continued)

(16) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with
MoparTEngine Oil Supplement, or equivalent. TheMoparTEngine Oil Supplement, or equivalent must
remain with the engine oil for at least 1609 km
(1,000 miles). The oil supplement need not be
drained until the next scheduled oil change.
(17) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(18) Check the ignition timing and adjust as nec-
essary.
(19) Install the grille and bumper, if removed.
(20) Connect negative cable to battery.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - FITTING
CONNECTING ROD BEARINGS
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Fig. 35) (Fig. 36). Check the
bearings for normal wear patterns, scoring, grooving,
fatigue and pitting (Fig. 37). Replace any bearing
that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
necting rod journals. If wear patterns or damage to
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
Fig. 33 Crankshaft / Camshaft Chain Drive
InstallationÐTypical
1 - CAMSHAFT SPROCKET
2 - TIMING MARKS
3 - CRANKSHAFT SPROCKET
Fig. 34 Timing Case Cover Components
1 - TIMING CASE COVER
2 - OIL SLINGER
3 - CRANKSHAFT OIL SEAL
4 - VIBRATION DAMPER PULLEY
Fig. 35 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
5 - LOWER BEARING HALF
WJENGINE - 4.0L 9 - 33
CAMSHAFT & BEARINGS (Continued)

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