spec JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

crankshaft is drilled internally to pass oil from the
main bearing journals (except number 4 main bear-
ing journal) to the connecting rod journals. Each con-
necting rod bearing cap has a small squirt hole, oil
passes through the squirt hole and is thrown off as
the rod rotates. This oil throwoff lubricates the cam-
shaft lobes, distributor drive gear, cylinder walls, and
piston pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. Oil is provided to the cam-
shaft bearing through galleries. The front camshaft
bearing journal passes oil through the camshaft
sprocket to the timing chain. Oil drains back to the
oil pan under the number one main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components,
then passes down through the push rod guide holes
in the cylinder head past the valve tappet area, and
returns to the oil pan (Fig. 73).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Disconnect connector and remove oil pressure
sending unit.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 or equivalent. Start engine and record pres-
sure. (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct pressures.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and
repeat inspection.If the oil leak source is not pos-itively identified at this time, proceed with the air
leak detection test method.
Air Leak Detection Test Method
(1) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
nipple.
(2) Remove the CCV valve from the cylinder head
cover. Cap or plug the CCV valve grommet.
(3) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service informa-
tion procedures.
(5) If the leakage occurs at the rear oil seal area,
INSPECTION FOR REAR SEAL AREA LEAKS .
(6) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the CCV valve and breather cap hose.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
WJENGINE - 4.0L 9 - 51
LUBRICATION (Continued)

(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in Maintenance Schedules.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug if
damaged.
(6) Install drain plug in crankcase.
(7) Replace engine oil filter. (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified
type of engine oil (Refer to LUBRICATION & MAIN-
TENANCE/FLUID TYPES - DESCRIPTION) and
amount of engine oil (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(9) Install oil fill cap.
(10) Start engine and inspect for leaks.
(11) Stop engine and inspect oil level. Refer to
CRANKCASE OIL LEVEL INSPECTION .
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used
engine oil after it has been drained from a vehicle
engine.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engine oil level indicator (Dipstick) is located
at the right rear of the 4.0L engine. Inspect engine
oil level approximately every 800 kilometers (500
miles). Unless the engine has exhibited loss of oil
pressure, run the engine for about five minutes
before checking oil level. Checking engine oil level on
a cold engine is not accurate.
To ensure proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
The acceptable levels are indicated between the ADD
and SAFE marks on the engine oil dipstick (Fig. 74).
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min-
utes for oil to settle to bottom of crankcase, remove
engine oil dipstick.
(3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading (Fig. 74).
(6) Add oil only if level is below the ADD mark on
dipstick.
OIL FILTER
REMOVAL
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Fig. 74 Engine Oil DipstickÐ4.0L Engine
1 - DIPSTICK
2 - ADD
3 - SAFE
WJENGINE - 4.0L 9 - 53
LUBRICATION (Continued)

All Jeep engines are equipped with a high quality
full-flow, throw-away type oil filter. DaimlerChrysler
Corporation recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss or filter
adapter housing (Fig. 75).
(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) Make sure old gasket comes off with oil filter.
With a wiping cloth, clean the gasket sealing surface
(Fig. 76) of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 76) hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
OIL PAN
DESCRIPTION
The oil pan is made of stamped steel. The oil pan
gasket is a one piece steel backbone silicone coated
gasket (Fig. 77).
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Remove the oil pan drain plug and drain the
engine oil.
(4) Disconnect the exhaust pipe at the exhaust
manifold.
(5) Disconnect the exhaust hanger at the catalytic
converter and lower the pipe.
(6) Remove the starter motor. (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - REMOV-
AL).
(7) Remove the engine flywheel and transmission
torque converter housing access cover.
(8) If equipped with an oil level sensor, disconnect
the sensor.
(9) Position a jack stand directly under the engine
vibration damper.
Fig. 75 Oil FilterÐ4.0L Engine
1 - CYLINDER BLOCK
2 - ADAPTER
3 - OIL FILTER
Fig. 76 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
Fig. 77 Oil Pan
1 - OIL PAN
2 - OIL PAN DRAIN PLUG
9 - 54 ENGINE - 4.0LWJ
OIL FILTER (Continued)

(9) Lower the engine until it is properly located on
the engine mounts.
(10) Install the through bolts and tighten the nuts.
(11) Lower the jack stand and remove the piece of
wood.
(12) Install the engine flywheel and transmission
torque converter housing access cover.
(13) Install the engine starter motor. (Refer to 8 -
ELECTRICAL/STARTING/STARTER MOTOR -
INSTALLATION).
(14) Connect the exhaust pipe to the hanger and to
the engine exhaust manifold.
(15) Install transmission oil cooling lines (if
equipped) and oxygen sensor wiring supports that
attach to the oil pan studs.
(16) Install the oil pan drain plug (Fig. 81).
Tighten the plug to 34 N´m (25 ft. lbs.) torque.
(17) Lower the vehicle.
(18) Connect negative cable to battery.
(19) Fill the oil pan with engine oil to the specified
level.
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 FAN. DO
NOT WEAR LOOSE CLOTHING.
(20) Start the engine and inspect for leaks.
ENGINE OIL PRESSURE
SENSOR
DESCRIPTION
The 3±wire, solid-state engine oil pressure sensor
(sending unit) is located in an engine oil pressure
gallery.
OPERATION
The oil pressure sensor uses three circuits. They
are:
²A 5±volt power supply from the Powertrain Con-
trol Module (PCM)
²A sensor ground through the PCM's sensor
return
²A signal to the PCM relating to engine oil pres-
sure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5±volt supply is sent to the sensor from the PCM
to power up the sensor. The sensor returns a voltage
signal back to the PCM relating to engine oil pres-
sure. This signal is then transferred (bussed) to theinstrument panel on either a CCD or PCI bus circuit
(depending on vehicle line) to operate the oil pressure
gauge and the check gauges lamp. Ground for the
sensor is provided by the PCM through a low-noise
sensor return.
OIL PUMP
REMOVAL
A gear-type oil pump is mounted at the underside
of the cylinder block opposite the No.4 main bearing.
(1) Drain the engine oil.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the pump-to-cylinder block attaching
bolts. Remove the pump assembly with gasket (Fig.
82).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
Fig. 82 Oil Pump Assembly
1 - OIL FILTER ADAPTOR
2 - BLOCK
3 - GASKET
4 - OIL INLET TUBE
5 - OIL PUMP
6 - STRAINER ASSEMBLY
7 - ATTACHING BOLTS
9 - 56 ENGINE - 4.0LWJ
OIL PAN (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)

ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DESCRIPTIONÐ4.7L ENGINE.............63
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........64
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........65
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............66
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION.............67
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE.............68
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......69
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........70
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........70
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........70
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............71
REMOVAL.............................71
INSTALLATION.........................73
SPECIFICATIONS
4.7L ENGINE.........................74
SPECIFICATIONS - 4.7L H.O. ENGINE.....77
TORQUE............................79
SPECIAL TOOLS
4.7L ENGINE.........................80
AIR CLEANER ELEMENT
REMOVAL - 4.7L........................83
INSTALLATION - 4.7L....................83
AIR CLEANER HOUSING
REMOVAL - 4.7L........................84
INSTALLATION - 4.7L....................84
CYLINDER HEAD - LEFT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........84
DESCRIPTION - VALVE GUIDES..........84
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................84
DIAGNOSIS AND TESTINGÐCYLINDER
HEAD GASKET.......................85
REMOVAL.............................85
CLEANING............................86
INSPECTION..........................87INSTALLATION.........................87
CAMSHAFT(S) - LEFT
DESCRIPTION.........................88
REMOVAL.............................89
INSTALLATION.........................90
CYLINDER HEAD COVER(S) - LEFT
DESCRIPTION.........................93
REMOVAL - LEFT SIDE..................93
CLEANING............................93
INSTALLATIONÐLEFT SIDE...............93
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................94
STANDARD PROCEDUREÐREFACING......94
REMOVAL.............................94
INSTALLATION.........................95
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION.........................96
REMOVAL.............................96
INSTALLATION.........................96
VALVE SPRINGS
DESCRIPTION.........................97
VALVE STEM SEALS
DESCRIPTION.........................97
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........97
DESCRIPTION - VALVE GUIDES..........97
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐCYLINDER
HEAD GASKET.......................97
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................98
REMOVAL.............................98
CLEANING............................99
INSPECTION..........................99
INSTALLATION.........................99
CAMSHAFT(S) - RIGHT
DESCRIPTION........................100
REMOVAL............................100
INSTALLATION........................102
CYLINDER HEAD COVER(S) - RIGHT
DESCRIPTION........................104
REMOVAL - RIGHT SIDE................104
CLEANING...........................104
INSTALLATION - RIGHT SIDE.............104
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................104
STANDARD PROCEDUREÐREFACING.....105
REMOVAL............................105
INSTALLATION........................106
WJENGINE - 4.7L 9 - 61

ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION........................107
REMOVAL............................107
INSTALLATION........................107
VALVE SPRINGS
DESCRIPTION........................108
VALVE STEM SEALS
DESCRIPTION........................108
ENGINE BLOCK
DESCRIPTION........................108
STANDARD PROCEDUREÐCYLINDER BORE
HONING...........................108
CLEANING...........................109
INSPECTION.........................109
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING...............109
CRANKSHAFT
DESCRIPTION........................111
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............111
REMOVAL............................112
INSPECTION..........................112
INSTALLATION........................112
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐCRANKSHAFT
MAIN BEARING - FITTING..............114
INSPECTION..........................115
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................115
INSTALLATION........................116
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................117
INSTALLATION........................117
FLEX PLATE
REMOVAL............................118
INSTALLATION........................118
PISTON & CONNECTING ROD
DESCRIPTION........................118
STANDARD PROCEDUREÐPISTON FITTING . 118
REMOVAL............................118
CLEANING...........................119
INSPECTION..........................119
INSTALLATION........................120
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................121
VIBRATION DAMPER
REMOVAL............................122
INSTALLATION........................123
STRUCTURAL COVER
DESCRIPTION........................124
OPERATION..........................124
REMOVAL............................124
INSTALLATION........................124
FRONT MOUNT
REMOVAL............................124INSTALLATION........................125
REAR MOUNT
REMOVAL............................125
INSTALLATION........................126
LUBRICATION
DESCRIPTION........................126
OPERATION..........................126
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................128
DIAGNOSIS AND TESTINGÐREAR SEAL
AREA LEAKS........................128
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAK..............................129
OIL
STANDARD PROCEDURE - ENGINE OIL....130
OIL FILTER
REMOVAL............................131
INSTALLATION........................132
OIL PAN
DESCRIPTION........................132
REMOVAL............................132
CLEANING...........................132
INSPECTION.........................132
INSTALLATION........................132
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION........................133
OPERATION..........................133
REMOVAL............................133
INSTALLATION........................133
OIL PUMP
REMOVAL............................134
DISASSEMBLY........................134
CLEANING...........................134
INSPECTION.........................134
ASSEMBLY...........................135
INSTALLATION........................135
INTAKE MANIFOLD
DESCRIPTION........................136
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE.................136
REMOVAL............................136
CLEANING...........................137
INSPECTION.........................137
INSTALLATION........................137
EXHAUST MANIFOLD - LEFT
DESCRIPTION........................138
REMOVAL............................138
CLEANING...........................138
INSPECTION.........................138
INSTALLATION........................138
EXHAUST MANIFOLD - RIGHT
DESCRIPTION........................139
REMOVAL............................139
CLEANING...........................140
INSPECTION.........................141
INSTALLATION........................141
9 - 62 ENGINE - 4.7LWJ

VALVE TIMING
DESCRIPTION - TIMING DRIVE SYSTEM....141
OPERATION - TIMING DRIVE SYSTEM.....141
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE TIMING
- VERIFICATION.....................141
STANDARD PROCEDUREÐMEASURING
TIMING CHAIN WEAR.................145TIMING BELT / CHAIN COVER(S)
REMOVAL............................146
INSTALLATION........................146
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL............................147
INSPECTION.........................149
INSTALLATION........................149
ENGINE - 4.7L
DESCRIPTIONÐ4.7L ENGINE
The 4.7 liter (287 CID) eight-cylinder engine is an
90É single overhead camshaft engine. The cast iron
cylinder block is made up of two different compo-
nents; the first component is the cylinder bore and
upper block, the second component is the bedplate
that comprises the lower portion of the cylinder block
and houses the lower half of the crankshaft mainbearings. The cylinders are numbered from front to
rear with the left bank being numbered 1,3,5 and 7,
and the right bank being numbered 2,4,6 and 8. The
firing order is 1±8±4±3±6±5±7±2. The engine serial
number is located at the right front side of the
engine block (Fig. 1)
WJENGINE - 4.7L 9 - 63

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or
mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)ÐPERFORMANCE and (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)ÐMECHANICAL for
possible causes and corrections of malfunctions.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING) and (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS
AND TESTING) for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following diagnosis:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING).
²Engine Cylinder Head Gasket Failure Diagnosis
(Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO-
SIS AND TESTING).
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
Fig. 1 Engine Identification Location
1 - VEHICLE VIN NUMBER LOCATION
2 - CYLINDER BLOCK RIGHT HAND SIDE
3 - CYLINDER BORE #2
9 - 64 ENGINE - 4.7LWJ
ENGINE - 4.7L (Continued)