Throttle cable JEEP GRAND CHEROKEE 2003 WJ / 2.G User Guide

(7) Remove the fan assembly from the water pump
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(8) Remove the fan shroud.
(9) Disconnect the transmission fluid cooler lines
(automatic transmission).
(10) Discharge the A/C system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(11) Remove the service valves and cap the com-
pressor ports.
(12) Remove the radiator or radiator/condenser (if
equipped with A/C).
(13) Disconnect the heater hoses at the engine
thermostat housing and water pump.
(14) Disconnect the accelerator cable, transmission
line pressure cable and speed control cable (if
equipped) from the throttle body.
(15) Remove cables from the bracket and secure
out of the way.
(16) Disconnect the body ground at the engine.
(17) Disconnect the following connectors and
secure their harness out of the way.
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
(18) Disconnect the coil rail electrical connections
and the oil pressure switch connector.
(19) Perform the fuel pressure release procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(20) Disconnect the fuel supply line at the injector
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(21) Remove the fuel line bracket from the intake
manifold.
(22) Remove the air cleaner assembly (Fig. 5).
(23) Disconnect the hoses from the fittings at the
steering gear.
(24) Drain the pump reservoir.
(25) Cap the fittings on the hoses and steering
gear to prevent foreign objects from entering the sys-
tem.
(26) Raise and support the vehicle.
(27) Disconnect the wires from the engine starter
motor solenoid.(28) Remove the engine starter motor (Refer to 8 -
ELECTRICAL/STARTING/STARTER MOTOR -
REMOVAL).
(29) Disconnect the oxygen sensor from the
exhaust pipe.
(30) Disconnect the exhaust pipe from the mani-
fold.
(31) Remove the exhaust pipe support.
(32) Remove the bending brace (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCT SUPPORT -
REMOVAL).
(33) Remove the engine flywheel/converter housing
access cover.
(34) Mark the converter and drive plate location.
(35) Remove the converter-to-drive plate bolts.
(36) Remove the upper engine flywheel/converter
housing bolts and loosen the bottom bolts.
(37) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(38) Lower the vehicle.
(39) Attach a lifting device to the engine.
(40) Raise the engine off the front supports.
(41) Place a support or floor jack under the con-
verter (or engine flywheel) housing.
(42) Remove the remaining converter (or engine
flywheel) housing bolts.
(43) Lift the engine out of the engine compart-
ment.
Fig. 5 Air Cleaner Assembly
1 - POWER STEERING PUMP
2 - AIR CLEANER ASSEMBLY
9 - 12 ENGINE - 4.0LWJ
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)

(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)

INSTALLATION
A gear-type oil pump is mounted at the underside
of the cylinder block opposite the No.4 main bearing.
(1) Install the oil pump on the cylinder block using
a replacement gasket. Tighten the bolts to 23 N´m
(17 ft. lbs.) torque.
(2) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(3) Fill the oil pan with oil to the specified level.
INTAKE MANIFOLD
DESCRIPTION
The intake manifold (Fig. 83) is made of cast alu-
minum and uses eleven bolts to mount to the cylin-
der head. This mounting style improves sealing and
reduces the chance of leaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Disconnect the battery negative cable.
(2) Remove air cleaner inlet hose from the resona-
tor assembly.
(3) Remove the air cleaner assembly.
(4) Remove the throttle cable, vehicle speed control
cable (if equipped) and the transmission line pres-
sure cable (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - AW4/THROTTLE VALVE
CABLE - REMOVAL).
(5) Disconnect the following electrical connections
and secure their harness out of the way:
²Throttle Position Sensor
²Idle Air Control Motor
²Coolant Temperature Sensor (at thermostat
housing)
²Intake Air Temperature Sensor
²Oxygen Sensor
²Crank Position Sensor
²Six (6) Fuel Injector Connectors
²Manifold Absolute Pressure (MAP) Sensor.
(6) Disconnect HVAC, and Brake Booster vacuum
supply hoses at the intake manifold.
(7) Perform the fuel pressure release procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(8) Disconnect and remove the fuel system supply
line from the fuel rail assembly.
(9) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(10) Remove the power steering pump from the
intake manifold and set aside.
(11) Raise the vehicle.
(12) Disconnect the exhaust pipes from the engine
exhaust manifolds.
(13) Lower the vehicle.
(14) Remove the intake manifold and exhaust
manifold bolts and manifolds (Fig. 84).
INSTALLATION
If the manifold is being replaced, ensure all the fit-
ting, etc. are transferred to the replacement mani-
fold.
(1) Install a new engine exhaust/intake manifold
gasket over the alignment dowels on the cylinder
head.
(2) Position the engine exhaust manifolds to the
cylinder head. Install fastener Number 3 and finger
tighten at this time (Fig. 84).
Fig. 83 Intake Manifold 4.0L Engine
WJENGINE - 4.0L 9 - 57
OIL PUMP (Continued)

(3) Install intake manifold on the cylinder head
dowels.
(4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 84).
(5) Install washer and fastener Numbers 6 and 7
(Fig. 84).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 84).
²Fastener Numbers 1 through 5ÐTighten to 33
N´m (24 ft. lbs.) torque.
²Fastener Numbers 6 and 7ÐTighten to 31 N´m
(23 ft. lbs.) torque.
²Fastener Numbers 8 through 11ÐTighten to 33
N´m (24 ft. lbs.) torque.
(7) Install the power steering pump to the intake
manifold.
(8) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the fuel system supply line to the fuel
rail assembly.
(10) Connect all electrical connections on the
intake manifold.
(11) Connect the vacuum hoses previously
removed.
(12) Install throttle cable, vehicle speed control
cable (if equipped).
(13) Install the transmission line pressure cable (if
equipped) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - AW4/THROTTLE VALVE
CABLE - INSTALLATION).
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the resonator assem-
bly.
(16) Raise the vehicle.
(17) Connect the exhaust pipes to the engine
exhaust manifolds. Tighten the bolts to 31 N´m (23
ft. lbs.)
(18) Lower the vehicle.(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust manifolds (Fig. 85) are log style
and are made of high silicon molybdenum cast iron.
The exhaust manifolds share a common gasket with
the intake manifold. The exhaust manifolds also
incorporate ball flange outlets for improved sealing
and strain free connections.
REMOVAL
The intake and engine exhaust manifolds on the
4.0L engine must be removed together. The manifolds
use a common gasket at the cylinder head.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - REMOVAL).
INSTALLATION
(1) The exhaust manifold and the intake manifold
must be installed together using a common gasket.
(2) (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - INSTALLATION).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) Remove the fan, hub assembly and fan shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL) (if equipped) and gen-
erator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 86).
INSTALLATION
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
Fig. 84 Intake and Exhaust Manifolds Installation
9 - 58 ENGINE - 4.0LWJ
INTAKE MANIFOLD (Continued)

(13) Disconnect the engine block heater power
cable from the block heater.
(14) Lower vehicle.
(15) Remove throttle body resonator assembly and
inlet hose.
(16) Disconnect throttle and speed control cables.
(17) Disconnect tube from both the left and right
side crankcase breathers, then remove the breathers
(Fig. 5).
(18) Discharge A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).(19) Remove radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL) and acces-
sory drive belt (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - REMOVAL).
(20) Remove A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - REMOVAL).
(21) Disconnect transmission oil cooler lines at the
radiator.
(22) Disconnect radiator lower hose at the thermo-
stat housing.
(23) Remove A/C condenser (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C CON-
DENSER - REMOVAL).
(24) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(25) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(26) Disconnect the two heater hoses from the tim-
ing chain cover.
(27) Disconnect engine harness at the following
points :
²Intake air temperature (IAT) sensor (Fig. 6)
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold absolute pressure (MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
(28) Release fuel rail pressure (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - STANDARD PROCE-
DURE) then disconnect the fuel supply quick connect
fitting at the fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(29) Remove power steering pump and position out
of the way.
(30) Disconnect ground straps from the left side of
the engine.
(31) Install Engine Lifting Fixture Special Tool
8347 (Fig. 7)following these steps.
²Holding the lifting fixture at a slight angle, slide
the large bore in the front plate over the hex portion
of the lifting stud.
²Position the two remaining fixture arms onto
the two lifting studs in the cylinder heads.
²Pull foward and upward on the lifting fixture so
that the lifting stud rest in the slotted area below the
large bore.
²Secure the lifting fixture to the three studs
using three 7/16 ± 14 N/C locknuts.
²Make sure the lifting loop in the lifting fixture is
in the last hole (closest to the throttle body) to min-
imize the angle of engine during removal.
Fig. 4 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
Fig. 5 Crankcase Breather Connection Points
1 - CRANKCASE BREATHERS
9 - 72 ENGINE - 4.7LWJ
ENGINE - 4.7L (Continued)

²Camshaft Position (CMP) Sensor
²Coil Over Plugs
(10) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(11) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(12) Install A/C condenser (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C CON-
DENSER - INSTALLATION).
(13) Connect radiator lower hose at the thermostat
housing.
(14) Connect the transmission oil cooler lines to
the radiator.
(15) Install A/C compressor. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(16) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION) and radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(17) Install breathers, then connect tube to both
crankcase breathers (Fig. 5).
(18) Connect throttle and speed control cables.
(19) Install throttle body resonator assembly and
inlet hose.
(20) Raise vehicle.
(21) Connect two ground straps on the lower left
hand side of the engine and one ground strap on the
lower right side.
(22) Install torque converter bolts.
(23) Connect crankshaft position sensor (Fig. 4).
(24) Install starter.
(25) Install rubber splash shield.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(26) Install structural cover (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION).
(27) Install exhaust crossover pipe.
(28) Install engine block heater power cable, If
equipped.
(29) Lower vehicle.
(30) Check and fill engine oil (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).
(31) Recharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(32) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(33) Connect the battery negative cable.
(34) Start engine and check for leaks.SPECIFICATIONS
4.7L ENGINE
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701cc
(287 Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Compression Ratio 9.0:1
Horsepower 235 BHP @ 4800 RPM
Torque 295 LB-FT @ 3200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Cylinder Block Cast Iron
Bore Diameter 93.010   .0075 mm
(3.6619   0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
PISTONS
Material Aluminum Alloy
Diameter 92.975 mm (3.6605 in.)
Weight 367.5 grams (12.96 oz)
Ring Groove Diameter
No. 1 83.73 - 83.97 mm
(3.296 - 3.269 in.)
No. 2 82.833 - 83.033 mm
(3.261 - 3.310 in.)
No. 3 83.88 - 84.08 mm
(3.302 - 3.310 in.)
PISTON PINS
Type Pressed Fit
Clearance In Piston 0.010 - 0.019 mm
(0.0004 - 0.0008 in.)
Diameter 24.013 - 24.016 mm
(0.9454 - 0.9456 in.)
9 - 74 ENGINE - 4.7LWJ
ENGINE - 4.7L (Continued)

INTAKE MANIFOLD
DESCRIPTION
The intake manifold is made of a composite mate-
rial and features long runners which maximizes low
end torque. The intake manifold uses single plane
sealing which consist of eight individual press in
place port gaskets to prevent leaks. Eight studs and
two bolts are used to fasten the intake to the head.
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove air cleaner housing and throttle body
resonator (Fig. 104).
(3) Disconnect throttle and speed control cables.
(4) Disconnect electrical connectors for the follow-
ing components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Disconnect vapor purge hose, brake booster
hose, speed control servo hose, positive crankcase
ventilation (PCV) hose.
Fig. 102 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 103 Oil Pump and Primary Timing Chain
Tensioner Tightening Sequence
Fig. 104 Throttle Body Resonator
1 - THROTTLE BODY RESONATOR
2 - BOLT
3 - BOLT
9 - 136 ENGINE - 4.7LWJ
OIL PUMP (Continued)