Valve cover torque JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION.........................55STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES.................55
TRANS COOLER
DESCRIPTION
An internal high capacity/high efficiency cooler is
used on all vehicles these coolers are an oil-to-coolant
type which consists of plates mounted in the radiator
outlet tank (Fig. 36). Because the internal oil cooler
is so efficient, no auxiliary oil cooler is offered The
cooler is not servicable seperatly from the radiator.
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
When a transmission failure has contaminated the
fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.
The only recommended procedure for flushing cool-
ers and lines is to use Tool 6906-B Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906-B.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents.DO NOTuse solvents containing acids, water,
gasoline, or any other corrosive liquids.(2) Reinstall filler plug on Tool 6906-B.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
(4) Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET
(To) cooler line
(7) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(11) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission Fluid.
(12) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
WJTRANSMISSION 7 - 55

INSTALLATION
(1) Connect engine harness connector to coil by
snapping into position. Move slide tab towards
engine (Fig. 15) for a positive lock.
(2) Position ignition coil rubber boots to all spark
plugs. Push down on coil assembly until bolt bases
have contacted cylinder head
(3) Install 4 coil mounting bolts. Loosely tighten 4
bolts just enough to allow bolt bases to contact cylin-
der head. Do a final tightening of each bolt in steps
down to 29 N´m (250 in. lbs.) torque. Do not apply
full torque to any bolt first.
(4) Connect negative battery cable to battery.
IGNITION COIL
DESCRIPTION
The 4.7L V±8 engine uses 8 dedicated, and individ-
ually fired coil (Fig. 16) for each spark plug. Each
coil is mounted directly to the top of each spark plug
(Fig. 17).
Fig. 15 Ignition Coil Electrical ConnectorÐ4.0L
6±Cylinder Engine
1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - SLIDE TAB
4 - RELEASE LOCK
5 - COIL CONNECTOR
Fig. 16 Ignition CoilÐ4.7L Engine
1 - O-RING
2 - IGNITION COIL
3 - ELECTRICAL CONNECTOR
Fig. 17 Ignition Coil LocationÐ4.7L Engine
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
WJIGNITION CONTROL 8I - 11
COIL RAIL (Continued)

SPECIFICATIONS
TORQUE - SPEED CONTROL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Servo Mounting Bracket-to-
Servo Nuts8.5 75
Servo Mounting Bracket-to-
Body Nuts28 6 250 50
Switch Module Mounting
Screws.6-1 6-9
Vacuum Reservoir Mounting
Bolts325
CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
REMOVAL
REMOVAL - 4.0L
(1) Disconnect negative battery cable at battery.
(2) Remove air box housing from throttle body.
(3) Using finger pressure only, remove speed con-
trol cable connector at throttle body bellcrank pin by
pushing connector off bellcrank pin towards drivers
side of vehicle (Fig. 1).DO NOT try to pull con-
nector off perpendicular to the bellcrank pin.
Connector will be broken.
(4) Remove cable from cable guide at top of valve
cover.
(5) Squeeze 2 release tabs (Fig. 1) on sides of cable
at bracket and push cable out of bracket.
(6) Remove servo cable from servo. Refer to Speed
Control Servo Removal/Installation.
REMOVAL - 4.7L
(1) Disconnect negative battery cable at battery.
(2) Remove air box housing from throttle body.
The accelerator cable must be partially removed to
gain access to speed control cable.(3) Using finger pressure only, disconnect accelera-
tor cable connector at throttle body bellcrank pin by
pushing connector off bellcrank pin towards front of
vehicle (Fig. 2).DO NOT try to pull connector off
perpendicular to the bellcrank pin. Connector
will be broken.
Fig. 1 Speed Control Cable at Bell CrankÐ4.0L
Engine
1 - ACCELERATOR CABLE
2 - OFF
3 - OFF
4 - THROTTLE BODY BELLCRANK
5 - SPEED CONTROL CABLE
6 - RELEASE TABS
7 - BRACKET
WJSPEED CONTROL 8P - 3
SPEED CONTROL (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE - 4.0L............................ 1ENGINE - 4.7L........................... 61
ENGINE - 4.0L
TABLE OF CONTENTS
page page
ENGINE - 4.0L
DESCRIPTION..........................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE..............8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......8
DIAGNOSIS AND TESTINGÐREAR SEAL
AREA LEAKS..........................9
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS..........9
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........10
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................10
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................10
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............11
REMOVAL.............................11
INSTALLATION.........................13
SPECIFICATIONS
ENGINE - 4.0L........................14
TORQUE - 4.0L ENGINE................17
AIR CLEANER ELEMENT
REMOVAL - 4.0L........................18
INSTALLATION - 4.0L....................19
AIR CLEANER HOUSING
REMOVAL - 4.0L........................19
INSTALLATION - 4.0L....................19CYLINDER HEAD
DESCRIPTION.........................19
REMOVAL.............................19
CLEANING............................21
INSPECTION..........................21
INSTALLATION.........................21
CYLINDER HEAD COVER(S)
DESCRIPTION.........................22
REMOVAL.............................22
CLEANING............................23
INSPECTION..........................23
INSTALLATION.........................23
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................23
STANDARD PROCEDURE - VALVE SERVICE . . 23
REMOVAL.............................25
INSTALLATION.........................25
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................26
CLEANING............................26
INSPECTION..........................27
INSTALLATION.........................27
VALVE STEM SEALS
DESCRIPTION.........................27
VALVE SPRINGS
DESCRIPTION.........................28
STANDARD PROCEDURE - VALVE SPRING
TENSION TEST.......................28
REMOVAL.............................28
INSTALLATION.........................29
ENGINE BLOCK
CLEANING............................30
INSPECTION..........................30
CAMSHAFT & BEARINGS
DESCRIPTION.........................30
WJENGINE 9 - 1

CONDITION POSSIBLE CAUSES CORRECTION
3. Thin or diluted oil 3. Change oil to correct viscosity.
4. Excessive main bearing clearance 4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing for
excessive wear on flanges
6. Crankshaft main journal out of
round or worn6. Grind journals or replace
crankshaft
7. Loose flywheel or torque converter 7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
5. Thin or diluted oil 5. Change oil to correct viscosity.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or cracked 9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated gaskets 1. Replace gasket
2. Loose fastener, broken or porous
metal part2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking3. Replace seal
4. Leaking oil gallery plug or cup
plug4. Remove and reseal threaded plug.
Replace cup style plug
EXCESSIVE OIL
CONSUMPTION OR SPARK
PLUGS OIL FOULED1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
WJENGINE - 4.0L 9 - 7
ENGINE - 4.0L (Continued)

INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the engine
flywheel.
(1) Attach a lifting device to the engine and lower
the engine into the engine compartment. For easier
installation, it may be necessary to remove the
engine mount bracket as an aid in alignment of the
engine to the transmission.
(2) Align the transmission torque converter hous-
ing with the engine.
(3) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on each
side.
(4) Tighten all 4 bolts finger tight.
(5) Install the engine mount brackets (if removed).
(6) Lower the engine and engine mount brackets
onto the engine compartment cushions. Install the
bolts and finger tighten the nuts.
(7) Remove the engine lifting device.
(8) Raise and support the vehicle.
(9) Install the remaining engine flywheel/converter
housing bolts. Tighten all bolts to 38 N´m (28 ft. lbs.)
torque.
(10) Install the converter-to-drive plate bolts.
(11) Ensure the installation reference marks are
aligned.
(12) Install the engine flywheel/converter housing
access cover.
(13) Install the exhaust pipe support and tighten
the screw.
(14) Install the engine bending brace (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCT SUPPORT -
INSTALLATION).
(15) Tighten the engine mount-to-bracket bolts.
(16) Connect the vehicle speed sensor wire connec-
tions and tighten the screws.
(17) Connect the exhaust pipe to the manifold.
(18) Install the engine starter motor (Refer to 8 -
ELECTRICAL/STARTING/STARTER MOTOR -
INSTALLATION).
(19) Connect the wires to the engine starter motor
solenoid.
(20) Lower the vehicle.
(21) Connect all the vacuum hoses and wire con-
nectors identified during engine removal.
(22) Remove protective caps from the power steer-
ing hoses.
(23) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 N´m (38 ft. lbs.)
torque.
(24) Fill the pump reservoir with fluid.(25) Inspect the fuel supply line o-ring(s) and
replace if necessary. Connect fuel supply line to injec-
tior rail and verify connection by pulling outward on
the line.
(26) Install the fuel line bracket to the intake
manifold.
(27) Connect the coil rail electrical connectors and
oil pressure switch connector.
(28) Connect the following electrical connectors:
²Power steering pressure switch
²Coolant temperature sensor
²Six (6) fuel injector connectors
²Intake air temperature sensor
²Throttle position sensor
²Map sensor
²Crankshaft position sensor
²Oxygen sensor
²Camshaft position sensor
²Generator connector and B+ terminal wire
(29) Connect all previously removed vacuum hoses.
(30) Connect the body ground strap.
(31) Install the throttle, transmission line pres-
sure, and speed control cables to their mounting
bracket and connect them to the throttle body.
(32) Connect the heater hoses at the engine ther-
mostat housing and water pump.
(33) Install the fan assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION).
(34) Place the fan shroud in position over the fan.
(35) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(36) Connect the service valves to the A/C com-
pressor ports, if equipped with A/C.
(37) Charge the air conditioner system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(38) Connect the radiator hoses and automatic
transmission fluid cooler pipes, if equipped.
(39) Install the fan shroud to the radiator or radi-
ator/condenser (if equipped with A/C).
(40) Install upper radiator support.
(41) Connect the upper radiator hose and tighten
the clamp.
(42) Connect the lower radiator hose and tighten
the clamp.
(43) Fill crankcase with engine oil. (Refer to
LUBRICATION & MAINTENANCE/FLUID CAPACI-
TIES - SPECIFICATIONS) for correct capacities.
(44) Fill the cooling system with reusable coolant
or new coolant (Refer to 7 - COOLING - STANDARD
PROCEDURE).
(45) Align the hood to the scribe marks. Install the
hood.
(46) Install the air cleaner assembly.
(47) Install the battery and connect the battery
cable.
WJENGINE - 4.0L 9 - 13
ENGINE - 4.0L (Continued)

(2) Lift cover up and position to the side.
(3) Remove air cleaner element.
INSTALLATION - 4.0L
(1) Clean inside of air cleaner housing before
installing new element.
(2) Install air cleaner element into housing.
(3) Latch clips and clamp cover down to secure. Be
sure air cleaner cover is properly seated to air
cleaner housing.
AIR CLEANER HOUSING
REMOVAL - 4.0L
(1) Disconnect air cleaner cover-to-air duct clamp
(Fig. 6).
(2) Disconnect air duct at housing.
(3)Each of the 3 air cleaner housing mount-
ing bolts is attached with 2 nuts (an upper nut
and lower nut). DO NOT REMOVE BOLTS. To
prevent stripping bolts, only remove lower
nuts. The lower housing nuts are located under
left front inner fender (Fig. 6).
(a) To gain access to lower nuts, raise vehicle.
(b) Remove clips retaining rubber inner fender
shield.
(c) Pry back shield enough to gain access to
lower nuts.
(d) Remove 3 nuts.
(e) Remove air cleaner assembly from vehicle.
(4) If resonator is to be removed, disconnect
breather tube at resonator, disconnect air duct clamp
at resonator (Fig. 6)and remove 1 resonator mount-
ing bolt. Remove resonator from throttle body by
loosening clamp (Fig. 7).
INSTALLATION - 4.0L
(1) Position air cleaner assembly to body and
install 3 nuts. Tighten nuts to 10 N´m (93 in. lbs.)
torque.To prevent excessive vibration transmit-
ted through housing, the nuts must be properly
torqued. Do not overtighten nuts.
(2) If resonator was removed: Install resonator and
bolts. Tighten bolts to 4 N´m (35 in. lbs.) torque.
Tighten clamp at throttle body to 4 N´m (35 in. lbs.)
torque.
(3) Position fender liner and install clips.
(4) Connect air duct at housing (Fig. 6).
(5) Tighten air duct clamp.
CYLINDER HEAD
DESCRIPTION
The cylinder head is made of cast iron containing
twelve valves made of chrome plated heat resistant
steel, valve stem seals, springs, retainers and keep-
ers. The cylinder head and valve seats can be resur-
faced for service purposes.
The valve guides are integral to the cylinder head,
They are not replaceable. However, they are service-
able.
The cylinder head uses dual quench-type design
combustion chambers which cause turbulence in the
cylinders allowing faster burning of the air/fuel mix-
ture, resulting in better fuel economy (Fig. 8).
REMOVAL
NOTE: This procedure can be done with the engine
in or out of the vehicle.
(1) Disconnect the battery negative cable.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Fig. 7 RESONATOR CLAMP - 4.0L
1 - RESONATOR
2 - AIR DUCT
3 - CLAMP
WJENGINE - 4.0L 9 - 19
AIR CLEANER ELEMENT (Continued)

CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
engine exhaust manifold and engine cylinder head
mating surfaces. Remove all gasket material and car-
bon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
INSTALLATION
NOTE: This procedure can be done with the engine
in or out of the vehicle.
The engine cylinder head gasket is a composition
gasket. The gasket is to be installed DRY.DO NOT
use a gasket sealing compound on the gasket.
If the engine cylinder head is to be replaced and
the original valves used, measure the valve stem
diameter. Only standard size valves can be used with
a service replacement engine cylinder head unless
the replacement head valve stem guide bores are
reamed to accommodate oversize valve stems.
Remove all carbon buildup and reface the valves.
(1) Remove the shop towels from the cylinder
bores. Coat the bores with clean engine oil.
(2) Position the engine cylinder head gasket (with
the numbers facing up) using the alignment dowels
in the cylinder block, to position the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) With bolt No.14 held in place (tape around
bolt), install the engine cylinder head over the same
dowels used to locate the gasket. Remove the tape
from bolt No.14.
(4) Coat the threads of stud bolt No.11 with Loc-
tite 592 sealant, or equivalent.
(5) Tighten the engine cylinder head bolts in
sequence according to the following procedure (Fig.
10).
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.(a) Tighten all bolts in sequence (1 through 14)
to 30 N´m (22 ft. lbs.) torque.
(b) Tighten all bolts in sequence (1 through 14)
to 61 N´m (45 ft. lbs.) torque.
(c) Check all bolts to verify they are set to 61
N´m (45 ft. lbs.) torque.
(d) Tighten bolts in sequence:
²Bolts 1 through 10 to 149 N´m (110 ft. lbs.)
torque.
²Bolt 11 to 135 N´m (100 ft. lbs.) torque.
²Bolts 12 through 14 to 149 N´m (110 ft. lbs.)
torque.
CYLINDER HEAD BOLTS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH DOWEL
POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
All bolts are 12 point drives for rocker cover clearance
(e) Check all bolts in sequence to verify the cor-
rect torque.
(f) If not already done, clean and mark each bolt
with a dab of paint after tightening. Should you
encounter bolts which were painted in an earlier
service operation, replace them.
(6) Install the spark plugs (Refer to 8 - ELECTRI-
CAL/IGNITION CONTROL/SPARK PLUG - INSTAL-
LATION).
(7) Connect the temperature sending unit wire
connector.
(8) Install the ignition coil rail (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/COIL RAIL -
INSTALLATION).
(9) Install the intake and exhaust manifolds (Refer
to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(10) Install the fuel line.
(11) Attach the power steering pump and bracket.
Fig. 10 Engine Cylinder Head Bolt Tightening
Sequence
WJENGINE - 4.0L 9 - 21
CYLINDER HEAD (Continued)

(12) Install the push rods, rocker arms, pivots and
bridges in the order they were removed (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - INSTALLATION).
(13) Install the engine cylinder head cover (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
(14) Attach the air conditioner compressor mount-
ing bracket to the engine cylinder head and block.
Tighten the bolts to 40 N´m (30 ft. lbs.) torque.
(15) Attach the air conditioning compressor to the
bracket. Tighten the bolts to 27 N´m (20 ft. lbs.)
torque.
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(16) Install the serpentine drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(17) Install the air cleaner and ducting.
(18) Connect the hoses to the engine thermostat
housing and fill the cooling system to the specified
level (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(19) The automatic transmission throttle linkage
and cable must be adjusted after completing the
engine cylinder head installation (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC - AW4/
THROTTLE VALVE CABLE - ADJUSTMENTS).
(20) Install the temperature sending unit and con-
nect the wire connector.
(21) If equipped with air conditioning, install A/C
compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION) and charge A/C system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(22) Connect negative cable to battery.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the engine thermostat opens. Add coolant, if
required.CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head cover (Fig. 11) is made of
stamped steel and incorporates the Crankcase Venti-
lation (CCV) Hoses and the oil fill opening.
REMOVAL
The cylinder head cover is isolated from the cylin-
der head via grommets and a reusable molded rubber
gasket. The grommet and limiter are retained in the
cylinder head cover.
(1) Disconnect negative cable from battery.
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover.
(3) Disconnect the fresh air inlet hose from the
engine cylinder head cover.
(4) Disconnect the accelerator, transmission, and
speed (if equipped) control cables from the throttle
body (Fig. 12).
(5) Remove the three bolts that fasten the control
cable bracket to the intake manifold.
(6) Remove control cables from cylinder head cover
clip.
(7) Position control cables and bracket away from
cylinder head cover secure with tie straps.
(8) Remove the engine cylinder head cover mount-
ing bolts.
(9) Remove the engine cylinder head cover and
gasket.
Fig. 11 Cylinder Head Cover
9 - 22 ENGINE - 4.0LWJ
CYLINDER HEAD (Continued)

CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original dark grey gasket material should
NOT be removed. If sections of the gasket material
are missing or are compressed, replace the engine
cylinder head cover. However, sections with minor
damage such as small cracks, cuts or chips may be
repaired with a hand held applicator. The new mate-
rial must be smoothed over to maintain gasket
height. Allow the gasket material to cure prior to
engine cylinder head cover installation.
INSTALLATION
The cylinder head cover is isolated from the cylin-
der head via grommets and a reusable molded rubber
gasket. The grommet and limiter are retained in the
cylinder head cover.
(1) If a replacement cover is installed, transfer the
CCV valve grommet and oil filler cap from the origi-
nal cover to the replacement cover.
(2) Install cylinder head cover and gasket (Fig. 13).
Tighten the mounting bolts to 10 N´m (85 in. lbs.)
torque.
(3) Connect the CCV hoses.(4) Install control cables and bracket on intake
manifold and tighten bolts to 8.7 N´m (77 in. lbs.)
torque.
(5) Connect control cables to throttle body linkage.
(6) Snap control cables into cylinder head cover
clip.
(7) Connect negative cable to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. All
valves use three bead locks to promote valve rotation
(Fig. 14).
STANDARD PROCEDURE - VALVE SERVICE
VALVE REFACING
Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 0.787 mm
(0.031 inch) must remain (Fig. 15). If the margin is
less than 0.787 mm (0.031 inch), the valve must be
replaced.
VALVE SEAT REFACING
Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
Fig. 12 Engine Cylinder Head Cover
1 - TRANS CONTROL CABLE
2 - ACCELERATOR CABLE
3 - CONTROL CABLE BRACKET
4 - CYLINDER HEAD COVER
Fig. 13 Cylinder Head Cover Gasket Locator Pins at
#8
WJENGINE - 4.0L 9 - 23
CYLINDER HEAD COVER(S) (Continued)