Jeep Wagoneer/Commando/Cherokee 1957-1983 Repair Information

Engine

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REMOVAL & INSTALLATION 4-134 Engines



FC-150 MODELS

The engine is removed from underneath the truck, along with the transmission and transfer case, as a unit, while the truck is resting on its wheels. Once the engine is resting on the floor, raise the front of the truck and slide the engine out. Engine removal is easier if you loosen the spring clips on the front axle and slide the axle forward as far as the brake hose will allow.

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the seats.
  2.  
  3. Remove the engine cover. Remove both halves of the engine housing.
  4.  
  5. Remove the radiator access cover.
  6.  
  7. Disconnect the battery.
  8.  
  9. Remove the radiator and heater hoses, and all other cooling system hoses.
  10.  
  11. Remove the coolant surge tank.
  12.  
  13. Remove the air cleaner and air cleaner bracket.
  14.  
  15. Remove the rear heater hose support bracket.
  16.  
  17. Remove the vacuum line which runs between the carburetor and distributor.
  18.  
  19. Remove the distributor. Tag the wires.
  20.  
  21. Disconnect the choke cable and wire.
  22.  
  23. Disconnect the throttle control wire at the carburetor and the accelerator cable at the distributor adapter.
  24.  
  25. Disconnect the fuel line at the carburetor.
  26.  
  27. Remove the carburetor.
  28.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the oil filler tube by pulling it straight out of the block.
  2.  
  3. Remove the ignition coil. Tag the wires.
  4.  
  5. Disconnect the oil filter hoses, and remove the filter and bracket.
  6.  
  7. Disconnect the wire at the temperature sending unit.
  8.  
  9. Disconnect the wires at the starter. Tag them.
  10.  
  11. Remove the rocker arm cover.
  12.  
  13. Remove the generator and bracket.
  14.  
  15. Remove the generator idler pulley and bracket.
  16.  
  17. Remove the fan.
  18.  
  19. Disconnect the vacuum line and fuel lines at the fuel pump.
  20.  
  21. Disconnect the exhaust pipe at the manifold.
  22.  
  23. Disconnect the transfer case linkage.
  24.  
  25. Disconnect the wire at the oil pressure sending unit.
  26.  
  27. Disconnect the transmission shift rods at the transmission and secure them out of the way.
  28.  
  29. Disconnect the clutch cable at the cross shaft and remove the cross shaft.
  30.  
  31. Disconnect the hand brake release spring.
  32.  
  33. Disconnect the hand brake cable and conduit and move it out of the way.
  34.  
  35. Disconnect the front and rear driveshafts at the transfer case. Secure them out of the way.
  36.  
  37. Disconnect the speedometer cable at the transfer case.
  38.  
  39. Attach a lifting bracket, using existing head bolts.
  40.  
  41. Take up the weight of the engine with a shop crane.
  42.  
  43. Remove the front engine mount bolts. Disconnect the ground strap.
  44.  
  45. Place a floor jack under the rear engine support crossmember. Remove the crossmember attaching bolts.
  46.  
  47. Raise the engine slightly to free it from the front mounts. Remove the floor jack.
  48.  
  49. Place wood blocks on the floor under the engine and lower the engine slowly, guiding it to the left and rearward. Allow the engine to rest on the wood blocks.
  50.  
  51. Remove the shop crane.
  52.  
  53. Raise and support the front end of the truck on jackstands and remove the engine from under the truck.
  54.  
  55. Installation is the reverse of removal. Observe the following torques:
  56.  



Engine mount bolts: 50 ft. lb.
 
Generator bracket-to-block: 25 ft. lb.
 
Exhaust pipe-to-manifold: 50 ft. lb.
 
Engine-to-bell housing bolts: 55 ft. lb.
 
Engine support crossmember: 30 ft. lb.
 

JEEPSTER/COMMANDO MODELS
  1. Remove the hood.
  2.  
  3. Remove the air cleaner and disconnect the air bleed hose from the carburetor.
  4.  
  5. Disconnect the battery.
  6.  
  7. Drain the engine oil and coolant.
  8.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the radiator hoses.
  2.  
  3. Remove the radiator and the grille support rods.
  4.  
  5. Remove the fan.
  6.  
  7. Disconnect and tag all wiring connected to the engine.
  8.  
  9. On engines equipped with an air pump, remove the pump, air manifold and diverter valve.
  10.  
  11. Remove the starter.
  12.  
  13. Disconnect the engine fuel line from the main fuel line at the frame rail.
  14.  
  15. Disconnect the throttle and choke cables from the carburetor.
  16.  
  17. Disconnect the exhaust pipe from the manifold.
  18.  
  19. Take up the weight of the engine with a shop crane.
  20.  
  21. Remove the front engine mount bolts.
  22.  
  23. Remove the engine-to-bell housing bolts.
  24.  
  25. Support the transmission with a floor jack.
  26.  
  27. Raise the engine slightly and move it forward to disengage it from the transmission.
  28.  
  29. When the engine is free, lift it from the vehicle.
  30.  
  31. Installation is the reverse of removal. Note the following torques:
  32.  



Engine front mount bolts: 15 ft. lb.
 
Starter mounting bolts: 25 ft. lb.
 
Exhaust pipe-to-manifold: 50 ft. lb.
 
Engine-to-bell housing bolts: 55 ft. lb.
 

6-325 Engines

  1. Remove the hood.
  2.  
  3. Disconnect the ground cable from the battery and the engine.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the engine oil from the crankcase and the engine coolant from the radiator.
  8.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the headlamp wiring from the block on the left fender.
  2.  
  3. Disconnect the horn wiring harness from the horn.
  4.  
  5. Disconnect the alternator wiring harness from the connector at the regulator.
  6.  
  7. Disconnect the upper and lower radiator hoses from the engine.
  8.  
  9. Disconnect the transmission oil cooler lines from the radiator, if the vehicle is equipped with an automatic transmission.
  10.  
  11. Remove the right and left radiator support bars.
  12.  
  13. Remove the cap screws and washers securing the right and left fenders to the cowl of the body.
  14.  
  15. Remove the bolt securing the radiator grille to the front frame crossmember and remove the front fenders, radiator and radiator grille as a unit from the vehicle.
  16.  
  17. Disconnect the engine wiring harness from the connectors located on the engine firewall.
  18.  
  19. Disconnect the battery cable and wiring from the engine starter assembly.
  20.  
  21. Remove the starter from the engine.
  22.  
  23. Disconnect the fuel hoses from the fuel lines at the right frame rail. Plug the lines to prevent leakage and the entrance of dirt.
  24.  
  25. Disconnect the throttle from the carburetor and cable support bracket mounted on the engine.
  26.  
  27. Disconnect the exhaust pipes from the right and left exhaust manifolds.
  28.  
  29. Place a jack under the transmission and support the weight of the transmission.
  30.  
  31. Remove the bolts securing the engine to the front motor mounts.
  32.  
  33. Attach a lifting device and support the weight of the engine.
  34.  
  35. Remove the bolts securing the engine to the flywheel housing.
  36.  
  37. Raise the engine slightly and slide the engine forward to remove the transmission mainshaft from the clutch plate spline.
  38.  

The engine and the transmission must be raised slightly to release the mainshaft from the clutch plate, while sliding the engine forward.

  1. When the engine is free of the transmission, raise the engine and remove it from the vehicle.
  2.  
  3. Install the engine in the reverse order of removal. Observe the following torques:
  4.  



Engine mount-to-block: 75 ft. lb.
 
Engine-to-bell housing: 40 ft. lb.
 
Starter-to-block: 40 ft. lb.
 
Starter-to-bracket: 12 ft. lb.
 



Remember to install the proper amount and type of oil in the crankcase and the proper mixture of coolant in the radiator before starting the engine. As soon as the engine is started, check for leaks of any type immediately. 6-226 Engines
 

The engine is removed from underneath the truck, along with the transmission and transfer case, as a unit, while the truck is resting on its wheels. Once the engine is resting on the floor, raise the front of the truck and slide the engine out. Engine removal is easier if you loosen the spring clips on the front axle and slide the axle forward as far as the brake hose will allow.

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the seats.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the radiator access cover.
  6.  
  7. Disconnect the battery.
  8.  
  9. Remove the radiator and heater hoses, and all other cooling system hoses.
  10.  
  11. Remove the coolant surge tank.
  12.  
  13. Remove the air cleaner and air cleaner bracket.
  14.  
  15. Remove the rear heater hose support bracket.
  16.  
  17. Remove the vacuum line which runs between the carburetor and distributor.
  18.  
  19. Remove the distributor. Tag the wires.
  20.  
  21. Disconnect the choke cable and wire.
  22.  
  23. Disconnect the throttle control wire at the carburetor and the accelerator cable at the distributor adapter.
  24.  
  25. Disconnect the fuel line at the carburetor.
  26.  
  27. Remove the carburetor.
  28.  
  29. Remove the oil filler tube by pulling it straight out of the block.
  30.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the ignition coil. Tag the wires.
  2.  
  3. Disconnect the oil filter hoses, and remove the filter and bracket.
  4.  
  5. Disconnect the wire at the temperature sending unit.
  6.  
  7. Disconnect the wires at the starter. Tag them.
  8.  
  9. Remove the generator housing.
  10.  
  11. Remove the generator and bracket.
  12.  
  13. Remove the generator idler pulley and bracket.
  14.  
  15. Remove the fan.
  16.  

Early models used a four-bladed fan. Willys recommended that owners of these vehicles replace the fan with the later six-bladed unit. If the original fan was attached with hex nuts and lockwashers, the new fan should be installed using elastic stop nuts.

  1. Disconnect the radiator brace at the engine mount and swing it out of the way.
  2.  
  3. Disconnect the vacuum line and fuel lines at the fuel pump.
  4.  
  5. Disconnect the exhaust pipe at the manifold.
  6.  
  7. Disconnect the transfer case linkage.
  8.  
  9. Disconnect the wire at the oil pressure sending unit.
  10.  
  11. Disconnect the engine ground strap.
  12.  
  13. Disconnect the transmission shift rods at the transmission and secure them out of the way.
  14.  
  15. Disconnect the clutch cable at the cross shaft and remove the cross shaft.
  16.  
  17. Disconnect the hand brake release spring.
  18.  
  19. Disconnect the hand brake cable and conduit and move it out of the way.
  20.  
  21. Disconnect the front and rear driveshafts at the transfer case. Secure them out of the way.
  22.  
  23. Disconnect the speedometer cable at the transfer case.
  24.  
  25. Attach a lifting bracket, using existing head bolts.
  26.  
  27. Take up the weight of the engine with a shop crane.
  28.  
  29. Remove the front engine mount bolts.
  30.  
  31. Place a floor jack under the rear engine support crossmember. Remove the crossmember attaching bolts.
  32.  
  33. Raise the engine slightly to free it from the front mounts. Remove the floor jack.
  34.  
  35. Place wood blocks on the floor under the engine and lower the engine slowly, guiding it to the left and rearward. Allow the engine to rest on the wood blocks.
  36.  
  37. Remove the shop crane.
  38.  
  39. Raise and support the front end of the truck on jackstands and remove the engine from under the truck.
  40.  
  41. Installation is the reverse of removal. Observe the following torques:
  42.  



Engine mount bolts: 50 ft. lb.
 
Generator bracket-to-block: 25 ft. lb.
 
Exhaust pipe-to-manifold: 50 ft. lb.
 
Engine support crossmember: 30 ft. lb.
 

6-230 Engines

  1. Raise and support the truck on jackstands.
  2.  
  3. Drain the oil from the engine.
  4.  
  5. Remove the oil filter.
  6.  
  7. Drain the coolant.
  8.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the hydraulic line at the clutch slave cylinder.
  2.  
  3. Remove the hood.
  4.  
  5. Remove the upper and lower radiator hoses.
  6.  
  7. Disconnect the automatic transmission cooler lines.
  8.  
  9. Remove the heater hoses.
  10.  
  11. Remove the radiator.
  12.  
  13. Disconnect and tag all wires attached to the engine.
  14.  
  15. Disconnect and tag any remaining hoses attached to the engine.
  16.  
  17. Remove the drive belts.
  18.  
  19. Remove the alternator.
  20.  
  21. Remove the fan and spacer.
  22.  
  23. Remove the battery and tray.
  24.  
  25. Unbolt the exhaust pipe from the manifold.
  26.  
  27. Remove the exhaust pipe from the bracket at the clutch housing.
  28.  
  29. Remove the carburetor.
  30.  
  31. Disconnect the fuel line at the frame.
  32.  
  33. Remove the front engine support bolts.
  34.  
  35. Take up the weight of the engine with a shop crane.
  36.  
  37. Remove the transfer case.
  38.  
  39. Remove the transmission.
  40.  
  41. Raise the engine slightly, pull it forward to clear the firewall and lift it out of the vehicle.
  42.  
  43. Installation is the reverse of removal. Torque the engine mount bolts to 25-30 ft. lb.
  44.  

6-232 and 6-258 Engines


CAUTION
Please refer to General Information and Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Matchmark the hood and hinges and remove the hood.
  2.  
  3. Drain the engine oil and the cooling system.
  4.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always rain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the battery.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the upper and lower radiator hoses.
  6.  
  7. Disconnect and cap the automatic transmission cooler lines.
  8.  
  9. Remove the fan shroud.
  10.  
  11. Remove the radiator.
  12.  
  13. Remove the fan and pulley.
  14.  
  15. Disconnect the accelerator linkage at the carburetor.
  16.  
  17. Remove the power steering pump and belt, but don't disconnect the hoses. Just move it out of the way.
  18.  
  19. On trucks with air conditioning, Discharge the system and remove the compressor and receiver-drier. Cap all line openings at once!
  20.  
  21. Disconnect and tag all wires, hoses, cables, vacuum lines, etc., connected to the engine or in the way of engine removal.
  22.  
  23. Remove the oil filter.
  24.  
  25. Remove both engine front support-to-frame nuts.
  26.  
  27. Disconnect the exhaust pipe at the support bracket and the manifold.
  28.  
  29. Take up the weight of the engine with a shop crane.
  30.  
  31. Remove the front engine support brackets.
  32.  
  33. Remove the transfer case shift lever boot, the carpeting and the transmission access plate.
  34.  
  35. Support the transmission with a floor jack.
  36.  
  37. Remove the upper engine-to-bellhousing bolts.
  38.  
  39. On engines built from 1971 and later, remove the starter.
  40.  
  41. On 1971 and later engines, equipped with automatic transmission, remove the two adapter plate inspection covers. Matchmark the torque converter and flex plate. Turning the engine by hand, remove each torque converter-to-flex plate bolt. Remove the remaining engine-to-bell housing bolts.
  42.  
  43. On trucks with manual transmission, remove the bell housing lower cover and remove the remaining engine-to-bell housing bolts.
  44.  
  45. Raise the engine, while guiding it forward and out of the vehicle.
  46.  
  47. Installation is the reverse of removal. Note the following torques:
  48.  



Lower engine-to-bell housing bolts: 43 ft.lb.
 
Upper engine-to-bell housing bolts: 27 ft.lb.
 
Exhaust pipe-to-manifold: 20 ft.lb.
 
Front support bracket nuts: 35 ft.lb.
 
Starter mounting bolts: 18 ft.lb.
 

8-304, 8-327, 8-350, 8-360 and 8-401 Engines


CAUTION
Please refer to General Information and Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Matchmark the hood and hinges and remove the hood.
  2.  
  3. Drain the engine oil and the cooling system.
  4.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the battery.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the upper and lower radiator hoses.
  6.  
  7. Disconnect and cap the automatic transmission cooler lines.
  8.  
  9. Remove the fan shroud.
  10.  
  11. Remove the radiator.
  12.  
  13. Remove the fan and pulley.
  14.  
  15. Disconnect the accelerator linkage at the carburetor.
  16.  
  17. Remove the power steering pump and belt, but don't disconnect the hoses. Just move it out of the way.
  18.  
  19. On trucks with air conditioning, Discharge the system and remove the compressor and receiver-drier. Cap all line openings at once!
  20.  
  21. Disconnect and tag all wires, hoses, cables, vacuum lines, etc., connected to the engine or in the way of engine removal.
  22.  
  23. On 1971 and later Wagoneers and J-Series trucks, remove the heater core housing and charcoal canister from the firewall.
  24.  
  25. Disconnect the automatic transmission filler tube from the bracket at the engine.
  26.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the oil filter.
  2.  
  3. Remove both engine front support-to-frame nuts.
  4.  
  5. Disconnect the exhaust pipes at the manifolds.
  6.  
  7. Take up the weight of the engine with a shop crane.
  8.  
  9. Remove the front engine support brackets.
  10.  
  11. Remove the transfer case shift lever boot, the carpeting and the transmission access plate.
  12.  
  13. Support the transmission with a floor jack.
  14.  
  15. Remove the upper engine-to-bellhousing bolts.
  16.  
  17. On engines built from 1971 and later, remove the starter.
  18.  
  19. On 1971 and later engines, equipped with automatic transmission, remove the two adapter plate inspection covers. Matchmark the torque converter and flex plate. Turning the engine by hand, remove each torque converter-to-flex plate bolt. Remove the remaining engine-to-bell housing bolts.
  20.  
  21. On trucks with manual transmission, remove the bell housing lower cover and remove the remaining engine-to-bell housing bolts.
  22.  
  23. Raise the engine, while guiding it forward and out of the vehicle.
  24.  
  25. Installation is the reverse of removal. Note the following torques:
  26.  



Lower engine-to-bell housing bolts: 43 ft. lb.
 
Upper engine-to-bell housing bolts: 27 ft. lb.
 
Exhaust pipe-to-manifold: 20 ft. lb.
 
Front support bracket nuts: 35 ft. lb.
 
Starter mounting bolts: 18 ft. lb.
 

 
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