1999–2004 Jeep Grand Cherokee Factory Shop Manual

• 12,471 PDF pages across 82 files — 2001 Service Manual: 2,059 pages; 2002 Service Manual (Publication No. 81-370-02064): 2,199; six 2002 diagnostic manuals: 1,980; 2002 WG diesel supplement: 291; 2004 system repair chapters: 3,107; 2004 Owner's Manual: 344; six Mopar parts catalogs: 2,477; short supplemental reference sheets: 14.
• Coverage is document-specific, not a single blanket 1999–2004 factory repair manual. Complete factory service-manual coverage is provided for 2001 and 2002, with 2004 supplied as individual system chapters; year-by-year illustrated parts coverage runs from 1999 through 2004.
• Covers 4.0L Power Tech I-6 and 4.7L/4.7L H.O. V8 engine removal, internal inspection, cylinder-head and valvetrain repair, timing-drive service, lubrication, cooling, fuel delivery, ignition, exhaust, and emissions; the 2.7L direct-injection diesel material applies specifically to 2002 WG models.
• Details 42RE, 45RFE/545RFE, and W5J400 automatic transmission diagnosis and service; NV147, NV242, and NV247 transfer cases; propeller shafts; and the related removal, disassembly, inspection, adjustment, and installation procedures.
• Includes 186FBI front, 198RBI rear, and 226RBA rear axle repair for standard, Trac-Lok, and Vari-Lok differentials, with pinion and carrier setup, axle shafts, seals, bearings, hubs, and housing service.
• Chassis chapters address the front and rear link/coil suspension, control arms, track bars, ball joints, knuckles, steering, disc brakes, Teves Mark 20 ABS, adjustable pedals, wheel alignment, and front-end noise, shimmy, pull, and vibration diagnosis.
• Provides DRBIII diagnostic routines, DTC and symptom flowcharts, no-start/no-code testing, module communication, programming and relearn procedures, connector and component-location views, PCI data-bus diagnosis, wiring diagrams, and illustrated parts references with VIN/application decoding.

Publication Makeup and Scope

The core 2001–2002 service and diagnostic PDFs are DaimlerChrysler publications, and the six illustrated parts books are Mopar catalogs. The 2004 repair files are separate Mitchell Repair Information Company system chapters, with DaimlerChrysler credited on many figures; they do not form one continuous 2004 factory service volume. Short trouble-code and spark-plug sheets are supplemental material.

The 2001 and 2002 books span maintenance, body, HVAC, electrical, powertrain, chassis, and driveline systems for 2WD/4x2 and 4WD/4x4 configurations. The separate 2.7L package is limited to 2002 WG vehicles and pairs the direct-injection diesel with its ECM/SKIS and W5J400 material.

Factory Diagnostic and Repair Depth

Six 2002 diagnostic volumes separate body, chassis, gasoline powertrain, diesel ECM/SKIS, W5J400, and 45RFE/545RFE work. The body book covers left- and right-hand-drive vehicles, PCI-bus communication, airbags, HVAC, cluster, memory seats, power locks and Remote Keyless Entry, tire-pressure monitoring, theft security, lighting, and wipers. Powertrain volumes add DTC, no-start/no-code, sensor and actuator, pressure-switch, quick-learn, adaptive, and verification routines. Tool references include the DRBIII scan tool, Miller transmission simulator 8333, and numbered installers, removers, and holding tools.

Drivetrain repair goes beyond routine fluid service. The axle sections cover shaft and seal replacement, pinion-seal work, differential disassembly, case and pinion bearings, pinion-depth selection, bearing preload, ring-gear backlash, tooth-contact checks, and final assembly. Transfer-case chapters address case disassembly, chains and sprockets, shift rails and forks, bearings, seals, and reassembly. Propeller-shaft inspection and operating-angle diagnosis support vibration troubleshooting.

The 4.0L and 4.7L engine chapters document removal and installation, cylinder-head and valvetrain work, timing components, pistons and connecting rods, crankshaft service, oil pumps, seals, cooling, fuel, ignition, and emissions systems. Component chapters include torque tables, approved lubricant and capacity data, inspection limits, clearances, and adjustment specifications. One important scope boundary: the 2004 automatic-transmission PDF is a servicing and adjustment chapter for the 42RE and 545RFE. It covers fluid/filter work, linkage, band adjustment, cooler service, and specifications, but not a complete 2004 internal transmission overhaul. Deeper internal repair and diagnostic coverage is in the earlier service books and dedicated transmission volumes.

Diagrams, Wiring, and Parts Identification

The 2004 wiring chapter alone contains 56 system diagrams, supported by component-location and fuse information elsewhere in the set. Representative references include 186FBI Measuring Pinion Gear Depth, Vari-Lok Differential Assembly, NV247 Transfer Case Assembly, Automatic A/C Circuit, Computer Data Lines Circuit, and 4.7L Engine Performance Circuit. They connect internal assemblies, adjustment points, connectors, modules, and test paths to the repair procedures that use them.

The six Mopar Illustration and Text catalogs cover chassis, body, and trim for each model year from 1999 through 2004. They provide exploded parts views, part numbers, quantities, VIN and body-code information, and powertrain, driveline, trim, and model application codes. This helps distinguish Laredo, Sport, Limited, and Overland applications and identify 2WD/4WD or powertrain-specific hardware before parts are ordered. The separate 2004 Owner's Manual covers operation, towing, maintenance, fluids, and safety; it does not replace the repair procedures.

Shop Notes

Several manual-specific cautions matter during real shop work. Rubber-bushed control-arm and suspension fasteners are final-tightened at normal ride height; tightening them with the suspension hanging can preload the bushings and shorten service life. During axle setup, the pinion nut is not backed off to reduce rotating torque—an over-compressed collapsible spacer can compromise bearing preload and requires corrective parts replacement. On the 4.7L timing system, the camshaft target wheel is not a holding point and must be protected from magnetism or distortion, either of which can contribute to a no-start condition.

Before axle, suspension, driveline, SRS, electrical, or HVAC repair, follow the publication's lift-point, battery-isolation, and refrigerant-handling precautions. Several covered jobs leave the vehicle or heavy assemblies unstable once mounting hardware is removed.