2002 JEEP GRAND CHEROKEE page 1

FRONT AXLE - 186FBI
TABLE OF CONTENTS
page page
FRONT AXLE - 186FBI
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING................16
REMOVAL.............................20
INSTALLATION.........................21
ADJUSTMENTS........................21
SPECIFICATIONS.......................30
SPECIAL TOOLS.......................31
AXLE SHAFTS
REMOVAL.............................34
INSTALLATION.........................34
AXLE SHAFT SEALS
REMOVAL.............................35
INSTALLATION.........................35
AXLE - C/V JOINT
REMOVAL.............................35
INSTALLATION.........................35
AXLE - U-JOINT
REMOVAL.............................36INSTALLATION.........................37
PINION SEAL
REMOVAL.............................37
INSTALLATION.........................37
COLLAPSIBLE SPACER
REMOVAL.............................39
INSTALLATION.........................39
DIFFERENTIAL
REMOVAL.............................40
DISASSEMBLY.........................42
ASSEMBLY............................42
INSTALLATION.........................43
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................44
INSTALLATION.........................44
PINION GEAR/RING GEAR
REMOVAL.............................45
INSTALLATION.........................46
FRONT AXLE - 186FBI
DESCRIPTION
The Front Beam-design Iron (FBI) axle consists of
a cast iron differential housing with axle shaft tubes
extending from either side. The tubes are pressed
into the differential housing and welded. The axles
are semi-floating axle shafts, meaning the loads are
supported by the hub bearings. The axle shafts are
retained by nuts at the hub bearings.
The differential case is a one-piece design. Differ-
ential bearing preload and ring gear backlash is
adjusted by the use of shims located between the dif-
ferential bearing cups and housing. Pinion bearing
preload is set and maintained by the use of a collaps-
ible spacer. A differential cover provides a means for
inspection and servicing.
An optional Vari-Loktdifferential has a one-piece
differential case which contains the gerotor pump
assembly and the clutch mechinism. This unit is ser-
viced as an assembly.
OPERATION
The axle receives power from the transfer case
through the front propeller shaft. The front propeller
shaft is connected to the pinion gear which rotatesthe differential through the gear mesh with the ring
gear bolted to the differential case. The engine power
is transmitted to the axle shafts through the pinion
mate and side gears. The side gears are splined to
the axle shafts.
STANDARD DIFFERENTIAL
During straight-ahead driving, the differential pinion
gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the pin-
ion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
WJFRONT AXLE - 186FBI 3 - 15

REAR AXLE - 198RBI
TABLE OF CONTENTS
page page
REAR AXLE - 198RBI
DESCRIPTION.........................50
OPERATION...........................50
DIAGNOSIS AND TESTING................51
REMOVAL.............................55
INSTALLATION.........................56
ADJUSTMENTS........................56
SPECIFICATIONS.......................65
SPECIAL TOOLS.......................66
AXLE SHAFTS
REMOVAL.............................69
INSTALLATION.........................69
AXLE BEARINGS/SEALS
REMOVAL.............................69
INSTALLATION.........................70
PINION SEAL
REMOVAL.............................71
INSTALLATION.........................71
COLLAPSIBLE SPACER
REMOVAL.............................73INSTALLATION.........................73
DIFFERENTIAL
REMOVAL.............................75
DISASSEMBLY.........................77
ASSEMBLY............................77
INSTALLATION.........................77
DIFFERENTIAL-TRAC-LOC
DIAGNOSIS AND TESTING................79
DISASSEMBLY.........................79
CLEANING............................82
INSPECTION..........................82
ASSEMBLY............................82
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................83
INSTALLATION.........................84
PINION GEAR/RING GEAR
REMOVAL.............................84
INSTALLATION.........................86
REAR AXLE - 198RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housing has
an iron center casting with axle shaft tubes extend-
ing from either side. The tubes are pressed into and
welded to the differential housing to form a one-piece
axle housing. The axles has semi-floating axle shafts,
meaning that loads are supported by the axle shaft
and bearings. The axle shafts are retained by bearing
retainer plates on the axles which are bolted to
flanges at the outboard end of the axle tubes.
The differential case is a one-piece design. Differ-
ential bearing preload and ring gear backlash is
adjusted by the use of selective spacer shims. Pinion
bearing preload is set and maintained by the use of a
collapsible spacer. A differential cover provides a
means for inspection and service.
Axles with optional Trac-Loktdifferential have a
one-piece differential case, and the same internal
components as a standard differential, plus two
clutch disc packs.
OPERATION
The axle receives power from the transmission/
transfer case through the rear propeller shaft. Therear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
STANDARD DIFFERENTIAL
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
3 - 50 REAR AXLE - 198RBIWJ

REAR AXLE - 226RBA
TABLE OF CONTENTS
page page
REAR AXLE - 226RBA
DESCRIPTION.........................90
OPERATION...........................90
DIAGNOSIS AND TESTING................92
REMOVAL.............................95
INSTALLATION.........................96
ADJUSTMENTS........................97
SPECIFICATIONS......................105
SPECIAL TOOLS.......................106
AXLE SHAFTS
REMOVAL............................109
INSTALLATION........................109
AXLE BEARINGS/SEALS
REMOVAL............................109
INSTALLATION........................110
PINION SEAL
REMOVAL............................111
INSTALLATION........................112
COLLAPSIBLE SPACER
REMOVAL............................113INSTALLATION........................114
DIFFERENTIAL
REMOVAL............................115
DISASSEMBLY........................117
ASSEMBLY...........................117
INSTALLATION........................117
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING...............119
DISASSEMBLY........................119
CLEANING...........................121
INSPECTION.........................121
ASSEMBLY...........................121
DIFFERENTIAL CASE BEARINGS
REMOVAL............................123
INSTALLATION........................123
PINION GEAR/RING GEAR
REMOVAL............................124
INSTALLATION........................126
REAR AXLE - 226RBA
DESCRIPTION
The Rear Beam-design Aluminum (RBA) axle hous-
ing has an aluminum center casting (differential
housing) with axle shaft tubes extending from either
side. The tubes are pressed into the differential hous-
ing to form a one-piece axle housing. The axle has
semi-floating axle shafts, meaning that vehicle load
is supported by the axle shaft and bearings.
The differential case is a one-piece design. Differen-
tial bearing preload and ring gear backlash is adjusted
with selective shims. Pinion bearing preload is set and
maintained by the use of a collapsible spacer. The cover
provides a means for inspection and service.
Optional Trac-Loktdifferential differential has a
one-piece differential case, and the same internal
components as a standard differential, plus two
clutch disc packs.
Optional Vari-Loktdifferential has a one-piece dif-
ferential case which contains the gerotor pump
assembly and the clutch mechinism. The unit is ser-
viced only as an assembly.
OPERATION
The axle receives power from the transfer case
through the front propeller shaft. The front propellershaft is connected to the pinion gear which rotates
the differential through the gear mesh with the ring
gear bolted to the differential case. The engine power
is transmitted to the axle shafts through the pinion
mate and side gears. The side gears are splined to
the axle shafts.
STANDARD DIFFERENTIAL
During straight-ahead driving the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must travel
a greater distance than the inside wheel to complete a
turn. The difference must be compensated for to prevent
the tires from scuffing and skidding through turns. To
accomplish this, the differential allows the axle shafts
to turn at unequal speeds (Fig. 2). In this instance, the
input torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to
rotate at a faster speed.
3 - 90 REAR AXLE - 226RBAWJ

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 41
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DESCRIPTION..........................2
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING............................5
STANDARD PROCEDURE - PRESSURE
BLEEDING............................5
SPECIFICATIONS
BRAKE COMPONENTS..................6
TORQUE CHART......................6
SPECIAL TOOLS
BASE BRAKES........................7
BRAKE FLUID LEVEL SWITCH
REMOVAL.............................7
INSTALLATION..........................7
RED BRAKE WARN INDICATOR SWITCH
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - RED BRAKE
WARNING LAMP.......................7
ADJUSTABLE PEDAL SWITCH
REMOVAL.............................8
INSTALLATION..........................8
BRAKE LINES
DESCRIPTION..........................8
DIAGNOSIS AND TESTING - BRAKE HOSES
AND LINES...........................8
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING....................9
STANDARD PROCEDURE - ISO FLARING . . . 9
BRAKE PADS / SHOES
DESCRIPTION
DESCRIPTION - FRONT DISC BRAKE
SHOES.............................10DESCRIPTION - REAR DISC BRAKE SHOES . 10
OPERATION
OPERATION - FRONT DISC BRAKE SHOES . 10
OPERATION - REAR DISC BRAKE SHOES . . 10
REMOVAL
REMOVAL- FRONT DISC BRAKE SHOES . . . 11
REMOVAL - REAR DISC BRAKE SHOES....12
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
SHOES.............................13
INSTALLATION - REAR DISC BRAKE
SHOES.............................14
DISC BRAKE CALIPERS
REMOVAL
REMOVAL - FRONT DISC BRAKE CALIPER . 14
REMOVAL - REAR DISC BRAKE CALIPER . . 15
DISASSEMBLY
DISASSEMBLY - FRONT DISC BRAKE
CALIPER............................17
DISASSEMBLY - REAR DISC BRAKE
CALIPER............................18
CLEANING - DISC BRAKE CALIPER.........19
INSPECTION - DISC BRAKE CALIPER.......19
ASSEMBLY
ASSEMBLY - FRONT DISC BRAKE CALIPER . 20
ASSEMBLY - REAR DISC BRAKE CALIPER . 21
INSTALLATION
INSTALLATION - FRONT DISC BRAKE
CALIPER............................22
INSTALLATION - REAR DISC BRAKE
CALIPER............................22
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................22
SPECIFICATIONS
BRAKE FLUID........................23
FLUID RESERVOIR
REMOVAL.............................23
WJBRAKES 5 - 1

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................41
OPERATION...........................41
DIAGNOSIS AND TESTING - ANTILOCK
BRAKES............................42
STANDARD PROCEDURE - BLEEDING ABS
BRAKE SYSTEM......................42
SPECIFICATIONS
TORQUE CHART......................42
ELECTRIC BRAKE
DESCRIPTION.........................43
OPERATION...........................43
FRONT WHEEL SPEED SENSOR
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................43INSTALLATION.........................43
G-SWITCH
DESCRIPTION.........................44
OPERATION...........................44
REMOVAL.............................44
INSTALLATION.........................44
REAR WHEEL SPEED SENSOR
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................46
OPERATION...........................46
REMOVAL.............................47
INSTALLATION.........................47
BRAKES - ABS
DESCRIPTION
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The hydraulic system is a three channel design.
The front brakes are controlled individually and the
rear brakes in tandem.
The ABS electrical system is separate from other
vehicle electrical circuits. A separate controller oper-
ates the system.
OPERATION
The antilock CAB activates the system whenever
sensor signals indicate periods of high wheel slip.
High wheel slip can be described as the point where
wheel rotation begins approaching 20 to 30 percent of
actual vehicle speed during braking. Periods of high
wheel slip occur when brake stops involve high pedal
pressure and rate of vehicle deceleration.
Battery voltage is supplied to the CAB ignition ter-
minal when the ignition switch is turned to Run posi-
tion. The CAB performs a system initialization
procedure at this point. Initialization consists of a
static and dynamic self check of system electrical
components.
The static check occurs after the ignition switch is
turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 30kph (18 mph). During the dynamic check, the CAB
briefly cycles the pump and solenoids to verify oper-
ation.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
ANTILOCK BRAKING
The antilock system prevents lockup during high
slip conditions by modulating fluid apply pressure to
the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. A sensor at each wheel converts wheel speed
into electrical signals. These signals are transmitted
to the CAB for processing and determination of
wheel slip and deceleration rate.
The ABS system has three fluid pressure control
channels. The front brakes are controlled separately
and the rear brakes in tandem. A speed sensor input
signal indicating a high slip condition activates the
CAB antilock program.
Two solenoid valves are used in each antilock con-
trol channel. The valves are all located within the
HCU valve body and work in pairs to either increase,
hold, or decrease apply pressure as needed in the
individual control channels.
The solenoid valves are not static during antilock
braking. They are cycled continuously to modulate
pressure. Solenoid cycle time in antilock mode can be
measured in milliseconds.
WJBRAKES - ABS 5 - 41

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 4.7L
ENGINE..............................1
DESCRIPTION - COOLING SYSTEM
ROUTING 4.7L ENGINE..................1
DESCRIPTIONÐCOOLING SYSTEM 4.0L
ENGINE..............................1
DESCRIPTIONÐCOOLING SYSTEM
ROUTING 4.0L ENGINE..................1
DESCRIPTIONÐHOSE CLAMPS...........1
OPERATION
OPERATIONÐCOOLING SYSTEM.........2
OPERATIONÐHOSE CLAMPS............2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)...................3
DIAGNOSIS AND TESTINGÐPRELIMINARY
CHECKS.............................3
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIAGNOSIS CHART.............5
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAKS......................10DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION.................12
STANDARD PROCEDURE
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 4.7L ENGINE.........12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 4.7L ENGINE.........12
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM - 4.0L ENGINE........13
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM - 4.0L ENGINE........13
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................13
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING..........14
SPECIFICATIONS
TORQUE............................14
SPECIAL TOOLS
COOLING...........................15
ACCESSORY DRIVE......................16
ENGINE...............................24
TRANSMISSION.........................55
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 4.7L
ENGINE
The cooling system consists of the following items:
²Hydraulic cooling fan and fan drive assembly
²Radiator
²Power steering oil cooler
²Radiator pressure cap
²Thermostat
²Coolant reserve/overflow system
²Transmission oil cooler (if equipped with an
automatic transmission)
²Coolant
²Water pump
²Hoses and hose clamps
DESCRIPTION - COOLING SYSTEM ROUTING
4.7L ENGINE
For cooling system routing refer to (Fig. 1).
DESCRIPTIONÐCOOLING SYSTEM 4.0L
ENGINE
The cooling system consists of:
²A radiator
²Mechanical Cooling Fan
²Thermal viscous fan drive-Low disengaged
²Fan shroud (Fig. 2)
²Radiator pressure cap
²Thermostat
²Coolant reserve/overflow system
²Transmission oil cooler (if equipped with an
automatic transmission)
²Coolant
²Water pump
²Hoses and hose clamps
²Accessory drive belt
DESCRIPTIONÐCOOLING SYSTEM ROUTING
4.0L ENGINE
For cooling system routing refer to (Fig. 3).
DESCRIPTIONÐHOSE CLAMPS
The cooling system utilizes both worm drive and
spring type hose clamps. If a spring type clamp
WJCOOLING 7 - 1

Carefully remove radiator pressure cap from filler
neck and check coolant level. Push down on cap to
disengage it from stop tabs. Wipe inside of filler neck
and examine lower inside sealing seat for nicks,
cracks, paint, dirt and solder residue. Inspect radia-
tor-to- reserve/overflow tank hose for internal
obstructions. Insert a wire through the hose to be
sure it is not obstructed.
Inspect cams on outside of filler neck. If cams are
damaged, seating of pressure cap valve and tester
seal will be affected.
Attach pressure tester (7700 or an equivalent) to
radiator filler neck (Fig. 6).
Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack in engine. Repair
as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL). Remove
Fig. 6 Pressure Testing Cooling SystemÐTypical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
WJCOOLING 7 - 11
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS
REMOVAL
REMOVALÐ4.7L ENGINE...............16
REMOVALÐ4.0L ENGINE...............16
INSTALLATION
INSTALLATIONÐ4.7L ENGINE...........16
INSTALLATIONÐ4.0L ENGINE...........17
DRIVE BELTS - 4.0L
DIAGNOSIS AND TESTING ± SERPENTINE
DRIVE BELT.........................17REMOVALÐ4.0L ENGINE.................19
INSTALLATIONÐ4.0L ENGINE.............19
DRIVE BELTS - 4.7L
DIAGNOSIS AND TESTING ± SERPENTINE
DRIVE BELT.........................20
REMOVAL - 4.7L ENGINE.................22
INSTALLATION - 4.7L ENGINE.............23
BELT TENSIONERS
REMOVAL
REMOVALÐ4.7L ENGINE
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from engine front
cover (Fig. 1).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
REMOVALÐ4.0L ENGINE
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from mounting
bracket (Fig. 2).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
INSTALLATION
INSTALLATIONÐ4.7L ENGINE
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
N´m (30 ft. lbs.).
Fig. 1 Automatic Belt Tensioner
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N´m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
7 - 16 ACCESSORY DRIVEWJ