Ect sensor JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Right Front Park/Turn Signal
Lamp (Except Built-Up-Export)BK At Lamp N/S
Right Front Side Marker Lamp
(Except Built-Up-Export)WT At Lamp N/S
Right Front Turn Signal Lamp
(Built-Up-Export)WT At Lamp N/S
Right Front Wheel Speed
SensorGY In Right Front Wheel Opening N/S
Right Headlamp Leveling
Motor (Built-Up-Export)BK At Motor N/S
Right High Beam Headlamp BK At Lamp N/S
Right Instrument Panel
SpeakerWT At Speaker 19, 20
Right Liftgate Ajar Switch BK In Liftgate 38
Right Low Beam Headlamp GY At Lamp N/S
Right Multi-Function Switch WT On Steering Column 23
Right Rear Door Lock
Motor/Ajar SwitchBK In Right Rear Door 29
Right Rear Door Speaker WT In Right Rear Door 29
Right Rear Lamp Assembly BK At Lamp Assembly 37
Right Rear Wheel Speed
SensorBK Near Right Rear Wheel 33, 35
Right Remote Radio Switch BK At Switch in Steering Wheel N/S
Right Side Repeater Lamp
(Built-Up-Export)BK On Right Front Fender 5
Right Visor/Vanity Lamp BK At Lamp N/S
Seat Belt Switch WT At Driver Seat N/S
Seat Module - C1 (Premium) BK Under Driver Seat N/S
Seat Module - C2 (Premium) OR Under Driver Seat N/S
Sentry Key Immobilizer Module BK On Steering Column 23
Shifter Assembly (Gas) WT Between Front Seats 23
Shifter Assembly C1 (Diesel) Between Front Seats N/S
Shifter Assembly C2 (Diesel) Between Front Seats N/S
Siren (Built-up-export) Left Front Fender 3, 4
Speed Control Switch NO. 1 BK On Steering Wheel N/S
Speed Control Switch NO. 2 BK On Steering Wheel N/S
Sunroof Control Module At Sunroof 32
Sunroof Motor C1 WT At Sunroof N/S
Sunroof Motor C2 BK In Overhead N/S
Sunroof Switch GY At Switch N/S
Temperature Valve Actuator
(MTC)BK On HVAC Housing N/S
Throttle Position Sensor (4.0L) BK Left Side of Engine 9
Throttle Position Sensor (4.7L) WT Left Side of Engine 13
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (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)

SPLICES
SPLICE
NUMBERLOCATION FIG.
S100 Near T/O for Power Distribution Center Eyelet 2
S102 (4.0L) Near T/O for G103 10, 11
102 (4.7L) Near T/O for Fuel Injector No. 1 13
S102 (Diesel) Near T/O for C110 7, 8
S103 (4.7L) Near T/O for Engine Oil Pressure Sensor 13
S104 (4.0L) Near T/O for A/C Compressor Clutch N/S
S104 (4.7L) Near T/O for Oxygen Sensor 2/2 Downstream N/S
S105 (4.0L) Near T/O for Capacitor 10 11
S105 (4.7L) Near T/O for Fuel Injector NO. 7 13
S106 (4.0L) In T/O for Oxygen Sensors 11, 12
S106 (4.7L) Near T/O for C103 14
S106 (4.7L) RHD Near T/O for Fuel Injector No.4 15
S107 (4.0L) Near T/O for Fuel Injector No.5 9
S107 (4.7L) Near T/O for Fuel Injector No.7 13
S109 (4.0L) Near T/O for Fuel Injector No.2 9
S109 (4.7L) Near T/O for Coil On Plug No. 6 14, 15
S110 (4.0L
Except
Built-Up-Export)Near T/O for Oxygen Sensor N/S
S111 (4.7L) In T/O for Oxygen Sensor N/S
S111 (4.0L
Except
Built-Up-Export)Near T/O for Oxygen Sensor N/S
S112 (4.0L) Near T/O for C102, C103 and C104 10, 11
S112 (4.7L) Near T/O for Coil On Plug No.8 15
S112 (Diesel) Near T/O for Accelerator Pedal Position Sensor N/S
S113 (4.7L) Near T/O for Transmission Control Module 15, 18
S114 (4.0L) Near T/O for Transmission Control Module 18
S114 (4.7L) Near T/O for Transmission Control Module 15, 18
S115 (4.0L) Near T/O for Transmission Control Module 18
S115 (4.7L) Near T/O for Transmission Control Module 15, 18
S116 (4.0L) Near Powertrain Control Module C1 and C2 18
S116 (4.7L) LHD Near T/O for C102, C103 and C104 14
S116 (4.7L) RHD In T/O for Powertrain Control Module 15
S117 (4.7L) LHD Neat T/O for C102, C103 and C104 14
S118 (4.7L) Near T/O for Coil On PlugNo.4 14, 15
S118 (Diesel) Near T/O for Fuel Sender Unit N/S
S119 (4.7L) LHD In T/O for Crankshaft Position Sensor 18
S119 (4.7L) RHD In T/O for Powertrain Control Module 15
S120 (4.7L) Near T/O for Powertrain Control Module 15, 18
S121 (4.7L) Near T/O for Idle Air Control Motor 13
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S122 (4.0L) Near T/O for G103 10, 11
S122 (4.7L) LHD Near T/O for Input Speed Sensor 15
S122 (4.7L) RHD Near T/O for Powertrain Control Module 16
S122 (Diesel) Near T/O for Generator N/S
S123 (4.0L) Near T/O for Capacitor 10, 11
S124 (4.7L) In Trough Near T/O for Capacitor No.2 13
S125 (Diesel) In T/O for C103 and C105 Left Rear of Engine Compartment N/S
S125 (Gas) Near T/O for Powertrain Control Module - C3 N/S
S126 (4.0L) LHD Near T/O for Battery Temperature Sensor N/S
S126 (4.0L) RHD In Trough Near T/O for Powertrain Control Module - C3 N/S
S127 (LHD) Gas In Trough Near T/O for Powertrain Control Module - C3 N/S
S127 (RHD) Gas In T/O for Power Distribution Center 5
S127 (Diesel) Near T/O for Power Distribution Center 4
S128 (Diesel) In T/O for C102 Left Rear of Engine Compartment N/S
S128 (LHD) Gas In Trough Near T/O for Powertrain Control Module - C3 N/S
S128 (RHD) Gas In T/O for C102 5
S130 (LHD) Gas In T/O for C102 N/S
S130 (RHD) Gas In T/O for Controller Antilock Brake 3
S130 (Diesel) In T/O for Controller Anti-Lock Brake 4
S131 In Trough Near T/O for Power Distribution Center 5
S131 (Diesel) Near T/O for Power Distribution Center 4
S132 (Diesel) Near T/O for EGR Solenoid N/S
S132 (Gas) Near T/O for Battery Temperature Sensor 5
S133 (Diesel) In Trough Near T/O for EGR Solenoid N/S
S133 (Gas) Near T/O for Battery Temperature Sensor 5
S134 (Diesel) In Trough Near T/O for G106/G107 4
S134 (Gas) In Trough Near T/O for Controller Anti-Lock Brake 3
S135 (Diesel) Near T/O for Engine Control Module C1 7, 8
S136 (Diesel) Near T/O for Engine Control Module C1 7, 8
S137 (Diesel) In Trough Near T/O for Coolant Level Sensor N/S
S139 (Diesel) Near T/O for Engine Control Module C1 7, 8
S140 (Diesel) Near T/O for Power Distribution Center 4
S140 (Gas) Near T/O for Controller Antilock Brake N/S
S141 (Gas) Near T/O for Controller Antilock Brake 3
S142 (Diesel) In Trough Near T/O for Coolant Level Sensor N/S
S142 Gas In T/O for C102 5
S143 (Diesel) In Trough Near T/O for Hood Ajar Switch 4
S143 (Gas,
Built-Up-Export)
LHDIn Trough Near T/O for Controller Antilock Brake 3
S143 Gas RHD Near T/O for Evap/Purge Solenoid N/S
S145 (Diesel) Near T/O for Engine Control Module C1 7, 8
WJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S147 (Diesel) In T/O for Controller Anti-Lock Brake 4
S151 In Headlamp Assembly N/S
S152 In Headlamp Assembly N/S
S153 In Headlamp Assembly N/S
S154 In Headlamp Assembly N/S
S155 In Headlamp Assembly N/S
S156 In Headlamp Assembly N/S
S158 4.7L RHD Near T/O for Fuel Injector No. 1 13
S159 In T/O for C101 N/S
S160 (4.7L High
Output)In T/O for C102 N/S
S162 (Diesel) In T/O for Wastegate Solenoid 4, 8
S163 Near T/O for Leak Detection Pump 3
S165 (Diesel) Near T/O for Left Front Wheel Speed Sensor 4
S168 Near T/O for Intake Air Temperature Sensor 7, 8
S169 Near T/O for Engine Control Module C1 7, 8
S170 Near T/O for Engine Control Module C2 7, 8
S171 Near T/O for C113 7
S172 Near T/O for C113 7
S174 Near Washer Fluid Level Switch Connector 3
S176 Near T/O for Intake Air Temperature Sensor 7
S200 In Trough Near T/O for Passenger Heated Seat Switch 21
S200 (RHD) Upper Center Instrument Panel 22
S201 In Trough Near T/O for Front Power Outlet 21
S201 (RHD) Near T/O for Power Connector 22
S202 In Trough Near T/O for Passenger Heated Seat Switch 21
S202 (RHD) Upper Center Instrument Panel 22
S203 In Trough Near T/O for Cigar Lighter 21
S203 (RHD) Lower Center Instrument Panel 22
S204 In Trough Near T/O for Power Connector 21
S204 (RHD) Right Center Instrument Panel 22
S205 Near T/O for Adjustable Pedal Switch 21
S205 (RHD) Upper Center Instrument Panel 22
S206 Near T/O for Adjustable Pedals Switch N/S
S206 (RHD) Upper Center Instrument Panel 22
S207 In Trough Near T/O for Radio Connectors 21
S207 (RHD) Upper Center Instrument Panel 22
S208 In Trough Near T/O for Radio Connectors 21
S208 (RHD) Upper Center Instrument Panel 22
S209 In Trough Near T/O for Left Courtesy Lamp 21
S209 (RHD) Lower Center Instrument Panel 22
S210 In Trough Near T/O for Left Courtesy Lamp 21
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

REMOVAL
REMOVAL - CAMSHAFT BEARINGS.......31
REMOVAL - CAMSHAFT................31
INSPECTION
INSPECTION - CAMSHAFT BEARINGS.....31
INSPECTION - CAMSHAFT..............31
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . . 32
INSTALLATION - CAMSHAFT............32
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - FITTING
CONNECTING ROD BEARINGS..........33
CRANKSHAFT
DESCRIPTION.........................35
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - FITTING
CRANKSHAFT MAIN BEARINGS..........36
REMOVAL.............................39
INSPECTION..........................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................41
INSTALLATION.........................41
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................42
INSTALLATION.........................42
HYDRAULIC LIFTERS
DESCRIPTION.........................43
REMOVAL.............................43
CLEANING............................43
INSPECTION..........................43
INSTALLATION.........................43
PISTON & CONNECTING ROD
DESCRIPTION.........................44
STANDARD PROCEDURE - PISTON FITTING . 44
REMOVAL.............................45
INSTALLATION.........................46
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................47
VIBRATION DAMPER
REMOVAL.............................49
INSTALLATION.........................49STRUCTURAL SUPPORT
REMOVAL.............................49
INSTALLATION.........................50
LUBRICATION
DESCRIPTION.........................50
OPERATION...........................50
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE..........................51
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK...............................51
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE............................53
OIL FILTER
REMOVAL.............................53
INSTALLATION.........................54
OIL PAN
DESCRIPTION.........................54
REMOVAL.............................54
INSTALLATION.........................55
ENGINE OIL PRESSURE SENSOR
DESCRIPTION.........................56
OPERATION...........................56
OIL PUMP
REMOVAL.............................56
INSTALLATION.........................57
INTAKE MANIFOLD
DESCRIPTION.........................57
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE..................57
REMOVAL.............................57
INSTALLATION.........................57
EXHAUST MANIFOLD
DESCRIPTION.........................58
REMOVAL.............................58
INSTALLATION.........................58
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................58
INSTALLATION.........................58
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................60
INSTALLATION.........................60
ENGINE - 4.0L
DESCRIPTION
The 4.0 Liter (242 CID) six-cylinder engine is an
In-line, lightweight, overhead valve engine. This
engine is designed for unleaded fuel.
The engine cylinder head has dual quench-type
combustion chambers that create turbulence and fast
burning of the air/fuel mixture. This results in better
fuel economy.
The cylinders are numbered 1 through 6 from front
to rear. The firing order is 1-5-3-6-2-4 (Fig. 1).The crankshaft rotation is clockwise, when viewed
from the front of the engine. The crankshaft rotates
within seven main bearings. The camshaft rotates
within four bearings.
The engine Build Date Code is located on a
machined surface on the right side of the cylinder
block between the No.2 and No.3 cylinders (Fig. 2).
The digits of the code identify:
²1st DigitÐThe year (8 = 1998).
²2nd & 3rd DigitsÐThe month (01 - 12).
²4th & 5th DigitsÐThe engine type/fuel system/
compression ratio (MX = A 4.0 Liter (242 CID) 8.7:1
compression ratio engine with a multi-point fuel
injection system).
9 - 2 ENGINE - 4.0LWJ

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE), for correct
procedures. Check charging system.
(Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING), for correct procedures.
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to 8
- ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
4. Siezed accessory drive
component4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical failure
or hydro-static lock5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), for
correct diagnostics/procedures
ENGINE CRANKS BUT WILL
NOT START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
SPECIFICATIONS), for correct
procedures.
2. No fuel 2. Perform fuel pressure test (Refer
to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING), and if
necessary, inspect fuel injector(s) and
driver circuits. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL
INJECTOR - DIAGNOSIS AND
TESTING), for correct procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn camshaft position sensor
shaft2. Remove and repair camshaft
position sensor.(Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
CAMSHAFT POSITION SENSOR -
REMOVAL).
9 - 4 ENGINE - 4.0LWJ
ENGINE - 4.0L (Continued)

(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)

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)