Connectors JEEP GRAND CHEROKEE 2003 WJ / 2.G Manual Online

(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)

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)

CYLINDER HEAD COVER(S) -
LEFT
DESCRIPTION
The cylinder head covers are made of die cast mag-
nesium, and are not interchangeable from side-to-
side. It is imperative that nothing rest on the
cylinder head covers. Prolonged contact with other
items may wear a hole in the cylinder head cover.
REMOVAL - LEFT SIDE
(1) Disconnect negative cable from battery.
(2) Remove the resonator assemble and air inlet
hose.
(3) Disconnect injector connectors and un-clip the
injector harness.
(4) Route injector harness in front of cylinder head
cover.
(5) Disconnect the left side breather tube and
remove the breather tube.(6) Remove the cylinder head cover mounting
bolts.
(7) Remove cylinder head cover and gasket.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSTALLATIONÐLEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all studs are in the correct loca-
tion shown in (Fig. 22).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs.).
(4) Install left side breather and connect breather
tube.
(5) Connect injector electrical connectors and injec-
tor harness retaining clips.
(6) Install the resonator and air inlet hose.
(7) Connect negative cable to battery.
Fig. 21 Tightening Left Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
Fig. 22 Cylinder Head CoverÐLeft
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
WJENGINE - 4.7L 9 - 93
CAMSHAFT(S) - LEFT (Continued)

CYLINDER HEAD COVER(S) -
RIGHT
DESCRIPTION
The cylinder head covers are made of die cast mag-
nesium, and are not interchangeable from side-to-
side. It is imperative that nothing rest on the
cylinder head covers. Prolonged contact with other
items may wear a hole in the cylinder head cover.
REMOVAL - RIGHT SIDE
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
(8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube.
(10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
(12) Remove cylinder head cover retaining bolts.
(13) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSTALLATION - RIGHT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.(2) Install cylinder head cover and hand start all
fasteners. Verify that all double ended studs are in
the correct location shown in (Fig. 38).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs).
(4) Install right rear breather tube and filter
assembly.
(5) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(6) Install the oil fill tube.
(7) Install PCV hose.
(8) Install heater hoses.
(9) Install air conditioning compressor retaining
bolts.
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Fill Cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. Each
valve is actuated by a roller rocker arm which pivots
on a stationary lash adjuster. All valves use three
bead lock keepers to retain the springs and promote
valve rotation.
Fig. 38 Cylinder Head CoverÐRight
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
9 - 104 ENGINE - 4.7LWJ

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)

(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(9) Install ignition coil towers (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/IGNITION COIL -
INSTALLATION).
(10) Install coolant temperature sensor (Refer to 7
- COOLING/ENGINE/ENGINE COOLANT TEMP
SENSOR - INSTALLATION).
(11) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(12) Install top oil dipstick tube retaining bolt and
ground strap.
(13) Install right side engine lifting stud.
(14) Install generator including electrical connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - INSTALLATION).
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Install air conditioning compressor including
electrical connections.
(17) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(18) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(19) Install cowl to hood seal (Refer to 23 - BODY/
WEATHERSTRIP/SEALS/COWL WEATHERSTRIP -
INSTALLATION).
(20) Install air cleaner housing and throttle body
resonator. Tighten resonator bolts 4.5 N´m (40 in.
lbs.).
(21) Connect negative cable to battery.
EXHAUST MANIFOLD - LEFT
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nutthat is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
(1) Disconnect negative cable for battery.
(2) Hoist vehicle.
(3) Disconnect exhaust pipe at manifold.
(4) Lower vehicle.
(5) Remove air cleaner housing and tube.
(6) Remove the front two exhaust heat shield
retaining fasteners. Raise vehicle and remove the
fasteners at rear of heat shield.
(7) Remove heat shield (Fig. 107).
(8) Lower vehicle and remove the upper exhaust
manifold retaining bolts (Fig. 107).
(9) Raise vehicle and remove the lower exhaust
manifold retaining bolts (Fig. 107).
(10) Remove exhaust manifold and gasket (Fig.
107). Manifold is removed from below the engine
compartment.
CLEANING
(1) Clean the exhaust manifold using a suitable
cleaning solvent, then allow to air dry.
(2) Clean all gasket residue from the manifold
mating surface.
INSPECTION
(1) Inspect the exhaust manifold for cracks in the
mating surface and at every mounting bolt hole.
(2) Using a straight edge and a feeler gauge, check
the mating surface for warp and twist.
(3) Inspect the manifold to exhaust pipe mating
surface for cracks, gouges, or other damage that
would prevent sealing.
INSTALLATION
(1) Install exhaust manifold and gasket from below
engine compartment.
(2) Install lower exhaust manifold fasteners (Fig.
107). DO NOT tighten until all fasteners are in
place.
(3) Lower vehicle and install upper exhaust mani-
fold fasteners (Fig. 107). Tighten all manifold bolts
starting at center and working outward to 25 N´m
(18 ft. lbs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) Install exhaust manifold heat shield (Fig. 107).
Tighten fasteners to 8 N´m (72 in. lbs.), then loosen
45 degrees.
(5) Install air cleaner housing and tube.
(6) Connect exhaust pipe to manifold.
(7) Connect negative cable to battery.
9 - 138 ENGINE - 4.7LWJ
INTAKE MANIFOLD (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRONT ABSORBER
REMOVAL.............................1
INSTALLATION..........................1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
REAR ABSORBER
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................4
FRAME
SPECIFICATIONS
SPECIFICATIONS - TORQUE.............4
FRAME DIMENSIONS...................4
FRONT SKID PLATE
REMOVAL.............................7INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
FUEL TANK SKID PLATE
DESCRIPTION..........................7
REAR TOW HOOK
REMOVAL.............................7
INSTALLATION..........................7
TRAILER HITCH
REMOVAL.............................8
INSTALLATION..........................8
TRANSFER CASE SKID PLATE
REMOVAL.............................8
INSTALLATION..........................8
FRONT ABSORBER
REMOVAL
(1) Remove front fascia, refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL).
(2) Remove the retainer attaching the absorber to
the fascia.
(3) Separate the absorber from the fascia.
INSTALLATION
(1) Position the absorber on the fascia.
(2) Install the retainer attaching the absorber to
the fascia.
(3) Install front fascia. Refer to (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
FRONT FASCIA
REMOVAL
(1) Raise and support vehicle.
(2) Turn front wheels to access rivets and remove
plastic rivets attaching fascia to wheel liner.
(3) Remove bolts attaching fascia to fender (Fig. 1).(4) Remove plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(5) Disengage fog lamp connectors, if equipped.
(6) Remove screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(7) Slide fascia forward to separate from vehicle.
INSTALLATION
(1) Slide fascia onto vehicle engaging fascia with
tabs on bottom of front fenders.
(2) Install screws attaching fascia/grille to upper
radiator crossmember (Fig. 3).
(3) Install bolts attaching fascia to fender (Fig. 1).
(4) Engage fog lamp connectors, if equipped.
(5) Install plastic rivets attaching fascia to wheel
liner.
(6) Install plastic push pin fasteners attaching
front fascia to lower radiator crossmember splash
shield (Fig. 2).
(7) Remove supports and lower vehicle.
WJFRAME & BUMPERS 13 - 1

CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tube (Fig. 22). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body air box.
(5) Remove air box at throttle body.
(6) Remove wiring at rear of generator.
(7) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(8) Remove vacuum lines at throttle body.(9) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 23). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(10) Disconnect electrical connectors at throttle
body.
(11) Disconnect electrical connectors at MAP and
IAT sensors.
Fig. 21 Fuel Injector Rail/Fuel DamperÐ4.0L Engine
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
10 - MOUNTING BOLTS (4)
11 - QUICK-CONNECT FITTING
Fig. 22 FUEL INJECTOR RAIL - 4.7L V-8 EN
1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
14 - 16 FUEL DELIVERYWJ
FUEL RAIL (Continued)

(12) Remove first three ignition coils on each bank
(cylinders #1, 3, 5, 2, 4 and 6). Refer to Ignition Coil
Removal/Installation.
(13) Remove 4 fuel rail mounting bolts (Fig. 22).
(14) Gently rock and pullleftside of fuel rail until
fuel injectors just start to clear machined holes in
cylinder head. Gently rock and pullrightside of rail
until injectors just start to clear cylinder head holes.
Repeat this procedure (left/right) until all injectors
have cleared cylinder head holes.
(15) Remove fuel rail (with injectors attached)
from engine.
(16) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
REMOVAL - 4.0L
The fuel damper is not serviced separately.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Disconnect negative battery cable from battery.(4) Remove air tube at top of throttle body. Note:
Some engine/vehicles may require removal of air
cleaner ducts at throttle body.
(5) Disconnect electrical connectors at all 6 fuel
injectors. To remove connector refer to (Fig. 25). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(6) Remove oxygen sensor wiring clip nuts at fuel
rail mounting studs (certain emissions packages
only).
(7) Disconnect fuel supply line latch clip and fuel
line at fuel rail. Refer to Quick-Connect Fittings.
(8) Disconnect throttle cable at throttle body. Refer
to Throttle Cable Removal/Installation.
Fig. 23 Remove/Install Injector ConnectorÐ4.7L V-8
Engine
Fig. 24 Fuel Rail MountingÐ4.0L Engine
1 - INJ. #1
2 - INJ. #2
3 - INJ. #3
4 - INJ. #4
5 - INJ. #5
6 - INJ. #6
7 - FUEL INJECTOR RAIL
8 - FUEL DAMPER
9 - PRESSURE TEST PORT CAP
10 - MOUNTING BOLTS (4)
11 - QUICK-CONNECT FITTING
WJFUEL DELIVERY 14 - 17
FUEL RAIL (Continued)