Jeep Wagoneer/Commando/Cherokee 1984-1998

Engine

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Removal & Installation



See Figure 1

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

  1. Disconnect the battery cables (negative cable first) and remove the battery. Remove the hood.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. On fuel injected engines only, relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner assembly.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, 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 quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the coolant and engine oil.
  2.  

If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. On models equipped with air conditioning, have the system discharged and evacuated by an MVAC, EPA-certified, automotive technician. Have the A/C compressor removed from the engine.
  2.  
  3. Remove the radiator assembly. If equipped with air conditioning, remove the condenser assembly.
  4.  
  5. Remove the engine cooling fan and install a 5 / 16 x 1 / 5 inch capscrew through the fan pulley into the water pump flange. This will maintain the pulley and water pump in alignment when the crankshaft is rotated.
  6.  
  7. Remove the heater hoses from the engine.
  8.  
  9. Tag and disconnect all hoses, wires, cables and linkages connected to the engine.
  10.  
  11. If necessary, remove the power brake vacuum check valve from the booster, if equipped.
  12.  
  13. If necessary, remove the distributor cap and wiring.
  14.  
  15. If necessary, remove the throttle body assembly.
  16.  
  17. If equipped with A/C, disconnect the hoses, then cap the compressor ports and hose openings.
  18.  
  19. Disconnect and plug the fuel lines at the fuel pump (diesel or carbureted engines) or at the fuel rail (on fuel injected engines).
  20.  
  21. If equipped, disconnect and drain the power steering hoses at the power steering pump or steering gear, whichever is the most convenient. Plug the hose openings to prevent system contamination.
  22.  
  23. If necessary, remove the power steering pump.
  24.  
  25. Raise and support the vehicle safely.
  26.  
  27. Remove the starter.
  28.  
  29. Remove the alternator.
  30.  
  31. Disconnect the exhaust pipe(s) from the manifold(s).
  32.  
  33. If necessary, remove the oil filter.
  34.  
  35. Remove the flywheel/converter housing access cover.
  36.  
  37. On vehicles equipped with an automatic transmission, matchmark the torque converter to the driveplate and remove the bolts.
  38.  
  39. If necessary, attach a C-clamp to the bottom of the torque converter housing to prevent the torque converter from coming out.
  40.  
  41. Remove the upper transmission housing-to-engine bolts and loosen the bottom bolts.
  42.  
  43. Lower the vehicle.
  44.  
  45. Attach a lifting device to the engine.
  46.  


WARNING
Do not lift the engine by the intake manifold.

  1. Take up the weight of the engine with the lifting device.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: The engine is secured to the vehicle by engine mounts

  1. Remove the engine mount bolts.
  2.  
  3. Raise the engine off the mounts.
  4.  
  5. Place a support jack under the transmission housing.
  6.  
  7. Remove the remaining engine-to-flywheel housing bolts.
  8.  
  9. On diesel models only, remove the reference pressure regulator from the dash panel.
  10.  
  11. Move the engine forward to clear the transmission, and carefully lift it out of the engine compartment.
  12.  
  13. Once the engine is removed from the vehicle, mount it on a suitable workstand.
  14.  
  15. If removed earlier, install the oil filter to keep foreign material out of the engine.
  16.  

To install:

Lightly oil all bolts and stud threads, except those specifying special sealant, prior to installation.

  1. Using the hoist or engine crane, slowly and carefully position the engine in the vehicle. Make sure the exhaust manifolds are properly aligned with the exhaust pipes.
  2.  

It may be easier to align the engine and transmission if you remove the engine mount cushions from the brackets.

  1. Align the engine to the transmission and install two engine-to-transmission bolts.
  2.  
  3. Install any engine mount cushions previously removed. Lower the engine onto the front engine mount cushions/insulators. Tighten the engine mount cushion nuts/bolts to the following values:

    All, except 5.2L/5.9L engines: 30 ft. lbs. (41 Nm)
     
    5.2L/5.9L Engines: 65 ft. lbs. (88 Nm)
     

  4.  
  5. Detach the engine crane or hoist from the engine.
  6.  
  7. Remove the floor jack from beneath the transmission.
  8.  
  9. Tighten the two installed engine-to-transmission bolts, then raise and securely support the vehicle on jackstands.
  10.  
  11. Install and tighten the remaining engine-to-transmission bolts to the following values:

    2.1L Engine: 30 ft. lbs. (41 Nm)
     
    2.5L Engine: upper bolts-27 ft. lbs. (37 Nm), lower bolts-43 ft. lbs. (58 Nm)
     
    2.8L Engine: 40 ft. lbs. (54 Nm)
     
    4.0L Engine (Cherokee/Comanche): 40 ft. lbs. (54 Nm)
     
    4.0L, 5.2L/5.9L Engines (Grand Cherokee): 30 ft. lbs. (41 Nm)
     

  12.  
  13. If equipped with automatic transmission, tighten the torque converter-to-drive plate bolts to the following values:

    2.1L Engine: 40 ft. lbs. (54 Nm)
     
    2.5L Engine: 40 ft. lbs. (54 Nm)
     
    2.8L Engine: 25 ft. lbs. (34 Nm)
     
    4.0L Engine (Cherokee/Comanche): 28 ft. lbs. (38 Nm)
     
    4.0L, 5.2L/5.9L Engines (Grand Cherokee): 23 ft. lbs. (31 Nm)
     

  14.  
  15. Install and tighten the front engine mount through-bolts to the following values:

    2.1L Engine: 48 ft. lbs. (65 Nm)
     
    2.5L Engine: 48 ft. lbs. (65 Nm)
     
    2.8L Engine: 92 ft. lbs. (125 Nm)
     
    4.0L Engine (Cherokee/Comanche): 48 ft. lbs. (65 Nm)
     
    4.0L Engine (Grand Cherokee): 89 ft. lbs. (121 Nm)
     
    5.2L/5.9L Engines: 60 ft. lbs. (81 Nm)
     

  16.  
  17. The remainder of installation is the reverse of the removal procedure. Be sure to tighten the fasteners to the values presented in the torque specification chart. Torque specifications not found in this section can be found in other sections covering those specific components.
  18.  


WARNING
Do NOT start the engine without first filling it with the proper type and amount of clean engine oil, and installing a new oil filter. Otherwise, severe engine damage will result.

  1. Fill the crankcase with the proper type and quantity of engine oil. If necessary, adjust the transmission and/or throttle linkage.
  2.  
  3. Check to make sure that all electrical wiring harnesses, linkages, ground wires, hoses, vacuum and fuel lines have been properly connected.
  4.  
  5. Check to make sure that all components have been installed properly.
  6.  
  7. Check to make sure that all adjustments have been performed, as well as all fasteners tightened properly.
  8.  
  9. Install the air intake duct assembly.
  10.  
  11. Install the battery into the vehicle. Connect the positive battery cable first, then connect the negative battery cable.
  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Start the engine and allow it to reach normal operating temperature, then check for leaks and proper operation.
  16.  
  17. Stop the engine and check all fluid levels.
  18.  
  19. Install the hood, aligning the marks that were made during removal.
  20.  
  21. If equipped, have the A/C system properly leak-tested, evacuated and charged by a MVAC-trained, EPA-certified, automotive technician.
  22.  
  23. Road test the vehicle.
  24.  

 
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