Cherokee, Grand Cherokee, 1999-2005

Engine

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Removal & Installation



2.5L & 4.0L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the power steering system.
  10.  
  11. Properly relieve the fuel system pressure.
  12.  
  13. Remove or disconnect the following:

    Battery
     
    Hood
     
    Air cleaner assembly
     
    Radiator hoses
     
    Fan shroud
     
    Electric cooling fan, if equipped
     
    Radiator
     
    Cooling fan
     
    Heater hoses
     
    Throttle cable
     
    Cruise control cable
     
    Transmission cable
     
    Fuel injector harness
     
    Camshaft Position (CMP) sensor connector
     
    Ignition coil wiring connector
     
    Oil pressure sender connector
     
    Body ground cable
     
    Starter solenoid connectors
     
    Fuel injection wiring harness
     
    Fuel line and bracket
     
    A/C compressor suction/discharge hose assembly
     
    Brake booster vacuum line
     
    Power steering hoses
     
    Intake manifold vacuum lines
     
    Crankshaft Position (CKP) sensor connector
     
    Engine speed sensor
     
    Oil filter
     
    Starter motor
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Exhaust front pipe
     
    Flywheel housing access cover
     
    Torque converter, if equipped with automatic transmission
     
    Transmission flange bolts
     
    Left and right motor mounts
     

  14.  
  15. Support the transmission and lift the engine out of the vehicle.
  16.  

To install:

  1. Lower the engine in to the vehicle and position to the transmission.
  2.  
  3. Install or connect the following:

    Left and right motor mounts. Tighten the through bolts to 51 ft. lbs. (69 Nm).
     
    Transmission flange bolts. Tighten the bolts to 28 ft. lbs. (38 Nm).
     
    Torque converter, if equipped with automatic transmission. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Flywheel housing access cover
     
    Exhaust front pipe
     
    Engine speed sensor electrical connector
     
    HO 2 S sensor connector
     
    Starter motor. Tighten the bolts to 33 ft. lbs. (45 Nm).
     
    Oil filter
     
    Vacuum hoses to the intake manifold
     
    CKP sensor connector
     
    Power steering hoses
     
    Brake booster vacuum line
     
    A/C compressor suction/discharge hose assembly
     
    Fuel line and bracket
     
    Fuel injection wiring harness
     
    Starter solenoid connectors
     
    Body ground cable
     
    Oil pressure sender connector
     
    Ignition coil wiring connector
     
    CMP sensor connector
     
    Fuel injector harness
     
    Transmission cable
     
    Cruise control cable
     
    Throttle cable
     
    Heater hoses
     
    Cooling fan
     
    Radiator
     
    Electric cooling fan, if equipped
     
    Fan shroud
     
    Radiator hoses
     
    Air cleaner assembly
     
    Hood
     
    Battery
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Fill and bleed the power steering system.

    charge the A/C system.
     

  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

3.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Air cleaner assembly
     
    Radiator
     
    Electric and mechanical fan assemblies
     
    A/C compressor, if equipped, and secure it out of the way with the lines attached. DO NOT DISCHARGE!
     
    Power steering pump, with the lines attached
     
    Alternator
     
    Coolant bottle
     
    Heater hoses
     
    Accelerator and speed control cables
     
    Lower and upper radiator hoses
     
    Engine ground straps
     
    Intake Air Temperature (IAT) sensor
     
    Fuel injection wiring connectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Oil pressure sender connector
     
    Engine Coolant Temperature (ECT) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft position sensor
     
    Ignition coil wiring connector
     
    Crankshaft Position (CKP) sensor
     
    Coil pack
     
    Fuel rail
     
    PCV hose
     
    Vacuum hoses from the intake manifold
     
    Knock sensor connectors
     
    Oil dipstick tube
     
    Intake manifold
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Block heater connector
     
    Front drive shaft at the differential
     
    Starter
     
    Structural cover
     
    With a manual transmission, remove the transmission
     
    Torque converter bolts and matchmark the converter
     
    Automatic transmission-to-engine bolts
     
    Exhaust front pipes
     
    Left and right engine mounts
     

  10.  
  11. Place a support stand under the transmission.
  12.  
  13. Install an engine lift plate
  14.  
  15. Lift the engine out of the vehicle.
  16.  

To install:

  1. If equipped with a manual transmission, install the transmission
  2.  
  3. Lower the engine and install the mounts. Don-t tighten the bolts yet.
  4.  
  5. If equipped with an automatic transmission, perform the following steps:
    1. Align the torque converter housing to the engine.
    2.  
    3. Torque the bolts to 30 ft. lbs. (41 Nm).

      Install the torque converter to flexplate bolts. Torque the bolts to 50 ft. lbs. (68 Nm).
       

    4.  

  6.  
  7. Install or connect the following:
    WARNING
    The structural cover must be held tightly against the engine and bell housing during tightening. The torque for all bolts is 40 ft. lbs. (54 Nm); the bolts must be tightened in the order shown.



    Torque the through bolts to 45 ft. lbs. (61 Nm).
     
    Engine ground strap
     
    Starter motor
     
    CKP sensor
     
    Block heater cable
     
    Structural cover.
     



    Click image to see an enlarged view

    Fig. Tighten the structural cover bolts in this order-3.7L



    Exhaust pipes. New flange clamps MUST be used!
     
    HO 2 S sensor connectors
     
    KS sensors
     
    Intake Manifold
     
    Dipstick tube
     
    Vacuum hoses to the intake manifold
     
    PCV and breather hoses
     
    Fuel rail
     
    Ignition coil
     
    IAT sensor
     
    Fuel injector connectors
     
    TP sensor
     
    IAC motor
     
    Oil pressure sender
     
    ECT sensor electrical connector
     
    MAP sensor
     
    CMP sensor
     
    Radiator hoses
     
    Cruise control cable, if equipped
     
    Throttle cable
     
    Heater hoses
     
    Coolant bottle
     
    Power steering pump
     
    Alternator
     
    A/C compressor
     
    Radiator
     
    Fan assemblies
     
    Air cleaner assembly
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the power steering system.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

4.0L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the power steering fluid.
  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Recover the A/C refrigerant.
  12.  
  13. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Radiator hoses
     
    Upper radiator support
     
    Cooling fan and shroud
     
    Radiator
     
    A/C condenser
     
    Heater hoses
     
    Accelerator cable
     
    Cruise control cable
     
    Transmission cable
     
    Body ground cable
     
    Power steering pressure switch connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Intake Air Temperature (IAT) sensor
     
    Fuel injector connectors
     
    Throttle Position (TP) sensor connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Crankshaft Position (CKP) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Ignition coil wiring connector
     
    Oil pressure sender connector
     
    Fuel line and bracket
     
    Air cleaner assembly
     
    Brake booster vacuum line
     
    Power steering hoses
     
    Starter motor
     
    Exhaust front pipe
     
    Flywheel cover
     
    Torque converter
     
    Transmission flange bolts
     
    Left and right motor mounts
     

  14.  
  15. Place a support stand under the transmission.
  16.  
  17. Lift the engine out of the vehicle.
  18.  

To install:

  1. Lower the engine in to the vehicle and position to the transmission.
  2.  
  3. Install or connect the following:

    Left and right motor mounts. Tighten the through bolts to 51 ft. lbs. (69 Nm).
     
    Transmission flange bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    Torque converter. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Flywheel cover
     
    Exhaust front pipe
     
    Starter motor. Tighten the bolts to 33 ft. lbs. (45 Nm).
     
    Power steering hoses
     
    Brake booster vacuum line
     
    Air cleaner assembly
     
    Fuel line and bracket
     
    Oil pressure sender connector
     
    Ignition coil wiring connector
     
    CMP sensor connector
     
    HO 2 S sensor connector
     
    CKP sensor connector
     
    MAP sensor connector
     
    TP sensor connector
     
    Fuel injector connectors
     
    IAT sensor
     
    ECT sensor connector
     
    Power steering pressure switch connector
     
    Body ground cable
     
    Transmission cable
     
    Cruise control cable
     
    Accelerator cable
     
    Heater hoses
     
    A/C condenser
     
    Radiator
     
    Cooling fan and shroud
     
    Upper radiator support
     
    Radiator hoses
     
    Hood
     
    Negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Fill and bleed the cooing system.
  8.  
  9. Fill the engine with clean oil
  10.  
  11. Recharge the A/C system.
  12.  
  13. Start the engine, check for leaks and repair if necessary.
  14.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the power steering system.
  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Recover the A/C refrigerant.
  12.  
  13. Remove or disconnect the following:

    Negative battery cable
     
    Front fascia
     
    Exhaust crossover pipe
     
    Engine ground straps
     
    Crankshaft Position (CKP) sensor
     
    Structural collar
     
    Starter
     
    Left and right inner fender liners
     
    Headlamp mounting module

    Click image to see an enlarged view

    Fig. Exploded view of the front fascia panel-2000-01 Grand Cherokee



    Click image to see an enlarged view

    Fig. Exploded view of the headlamp module assembly-2000-01 Grand Cherokee

     



    Air intake resonator
     
    Accelerator cable
     
    Cruise control cable
     
    Crankcase breather tubes
     
    Accessory drive belt
     
    A/C compressor
     
    Cooling fan assemblies
     
    Radiator hoses
     
    Transmission oil cooler lines
     
    Radiator
     
    A/C condenser
     
    Alternator
     
    Heater hoses
     
    Throttle Position (TP) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Fuel injector harness connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Ignition coils
     
    Fuel line
     
    Power steering pump
     
    Oil fill tube
     
    Oil dipstick tube
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Engine oil filter
     
    Exhaust crossover pipe
     
    Structural cover
     
    Rubber splash shield
     
    Starter motor
     
    Crankshaft Position (CKP) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Torque converter
     
    Engine ground straps
     
    Left and right motor mounts
     
    Transmission flange bolts
     

  14.  
  15. Install Engine Lifting Fixture 8347 as shown.

    Click image to see an enlarged view

    Fig. Engine Lifting Fixture-4.7L engine

  16.  
  17. Place a support stand under the transmission.
  18.  
  19. Lift the engine out of the vehicle.
  20.  

To install:

  1. Lower the engine in to the vehicle and position to the transmission.
  2.  
  3. Remove the engine lifting fixture.
  4.  
  5. Install or connect the following:

    Transmission flange bolts. Tighten the bolts to 50 ft. lbs. (68 Nm).
     
    Left and right motor mounts. Tighten the bolts to 45 ft. lbs. (61 Nm).
     
    Engine ground straps
     
    Torque converter. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    CMP sensor connector
     
    CKP sensor connector
     
    Starter motor
     
    Rubber splash shield
     

  6.  
  7. Install the structural cover as follows:
    1. Install all the bolts finger-tight.
    2.  
    3. Hold the cover tightly against the transmission and the engine.
    4.  
    5. Tighten the bolts in sequence to 40 ft. lbs. (54 Nm).

      Click image to see an enlarged view

      Fig. Structural cover torque sequence-4.7L engine

    6.  

  8.  
  9. Install or connect the following:

    Exhaust crossover pipe
     
    Engine oil filter
     
    HO 2 S sensor connectors
     
    Oil dipstick tube
     
    Oil fill tube
     
    Power steering pump
     
    Fuel line
     
    Ignition coils
     
    MAP sensor connector
     
    IAC valve connector
     
    ECT sensor connector
     
    Fuel injector harness connectors
     
    IAT sensor connector
     
    TP sensor connector
     
    Heater hoses
     
    Alternator
     
    A/C condenser
     
    Radiator
     
    Transmission oil cooler lines
     
    Radiator hoses
     
    Cooling fan assemblies
     
    A/C compressor
     
    Accessory drive belt
     
    Crankcase breather tubes
     
    Cruise control cable
     
    Accelerator cable
     
    Air intake resonator
     
    Headlamp mounting module
     
    Left and right inner fender liners
     
    Front fascia
     
    Negative battery cable
     

  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Fill and bleed the power steering system.

    Fill the engine with clean oil.
     

  14.  
  15. Recharge the A/C system.
  16.  
  17. Start the engine, check for leaks and repair if necessary.
  18.  

5.7L Engine
  1. Remove the strut tower support.
  2.  
  3. Remove the engine cover.
  4.  
  5. Perform the Fuel System Pressure Release procedure.
  6.  
  7. Disconnect the battery negative cable.
  8.  
  9. Remove the air cleaner resonator and duct work as an assembly.
  10.  
  11. Drain cooling system.
  12.  
  13. Remove the accessory drive belt.
  14.  
  15. Remove radiator fan shroud.
  16.  
  17. Remove the A/C compressor with the lines attached. Secure compressor out of the way.
  18.  
  19. Remove generator assembly.
  20.  
  21. Remove the intake manifold and IAFM as an assembly.
  22.  
  23. Remove the ground wires from the rear of each cylinder head.
  24.  
  25. Disconnect the heater hoses.
    NOTE
    It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.

  26.  
  27. Remove the power steering pump and set aside.
  28.  
  29. Disconnect the fuel supply line.
  30.  
  31. Raise and support the vehicle on a hoist and drain the engine oil.
  32.  
  33. Remove engine front mount to frame bolts and nuts.
  34.  
  35. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
  36.  
  37. Disconnect exhaust pipe at manifolds.
  38.  
  39. Disconnect the starter wires. Remove starter motor.
  40.  
  41. Remove the structural dust cover.
  42.  
  43. Remove drive plate to converter bolts.
  44.  
  45. Remove the oil pan to transmission bolts.
  46.  
  47. Remove transmission bell housing to engine block bolts.
  48.  
  49. Lower the vehicle.
  50.  
  51. Install engine lift fixture, special tool # 8984 and 8984-UPD.
  52.  
  53. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
  54.  

To install:

  1. Install engine lift fixture Special tool # 8984 and 8984-UPD.
  2.  
  3. Position the engine in the engine compartment.
  4.  
  5. Lower engine into compartment and align engine with transmission.
  6.  
  7. Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
  8.  
  9. Lower engine assembly until the engine mounts rests in frame perches.
  10.  
  11. Install remaining transmission to engine block mounting bolts and the oil pan to transmission bolts and tighten.
  12.  
  13. Install and tighten engine mount to frame bolts and nuts.
  14.  
  15. Install drive plate to torque converter bolts.
  16.  
  17. Install the structural dust cover.
  18.  
  19. Install the starter and connect the starter wires.
  20.  
  21. Install exhaust pipe to manifold.
  22.  
  23. Lower the vehicle.
  24.  
  25. Remove engine lift fixture, special tool # 8984 and 8984-UPD.
  26.  
  27. Connect the fuel supply line.
  28.  
  29. Reinstall the power steering pump.
  30.  
  31. Connect the heater hoses.
  32.  
  33. Reconnect the ground wires to the rear of each cylinder head.
  34.  
  35. Install the intake manifold.
  36.  
  37. Install the generator, and wire connections.
  38.  
  39. Install a/c compressor.
  40.  
  41. Install the accessory drive belt.
  42.  
  43. Install the radiator fan shroud.
  44.  
  45. Connect the radiator lower hose.
  46.  
  47. Connect the transmission oil cooler lines to the radiator.
  48.  
  49. Connect the radiator upper hose.
  50.  
  51. Install the air cleaner resonator and duct work..
  52.  
  53. Add engine oil to crankcase.
  54.  
  55. Fill cooling system.
  56.  
  57. Install the engine cover.
  58.  
  59. Install the strut tower support.
  60.  
  61. Connect battery negative cable.
  62.  
  63. Start engine and inspect for leaks.
  64.  
  65. Road test vehicle.
  66.  

 
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