2003 JEEP GRAND CHEROKEE Tools

the same time, the power distribution system was
designed to provide ready access to these electrical
distribution points for the vehicle technician to use
when conducting diagnosis and repair of faulty cir-
cuits. The power distribution system can also prove
useful for the sourcing of additional electrical circuits
that may be required to provide the electrical current
needed to operate accessories that the vehicle owner
may choose to have installed in the aftermarket.
NOTE: DO NOT ATTEMPT TO SWAP POWER DIS-
TRIBUTION CENTERS FROM ONE VEHICLE TO
ANOTHER. MOST OF THESE ASSEMBLIES ARE
VEHICLE FEATURE SPECIFIC AND THEREFORE
NOT INTERCHANGEABLE. ALWAYS USE THE COR-
RECT PART NUMBERED ASSEMBLY WHEN DIAG-
NOSING OR REPLACING A POWER DISTRIBUTION
CENTER.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
A cigar lighter outlet is standard equipment on
this model. On models equipped with the optional
Smoker's Package, the cigar lighter knob and heating
element are included. On models without the Smok-
er's Package, the cigar lighter outlet is equipped with
a snap fit plastic cap and is treated as an extra
accessory power outlet. The cigar lighter outlet is
installed in the instrument panel center lower bezel,
which is located near the bottom of the instrument
panel center stack area, below the heater and air
conditioner controls. The cigar lighter outlet is
secured by a snap fit within the center lower bezel.The cigar lighter outlet, plastic cap and the knob
and heating element unit are available for service
replacement. These components cannot be repaired
and, if faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or outlet shell. The receptacle shell is
connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The cigar lighter receives battery voltage from a fuse
in the junction block when the ignition switch is in
the Accessory or On positions.
The cigar lighter knob and heating element are
encased within a spring-loaded housing, which also
features a sliding protective heat shield. When the
knob and heating element are inserted in the outlet
shell, the heating element resistor coil is grounded
through its housing to the outlet shell. If the cigar
lighter knob is pushed inward, the heat shield slides
up toward the knob exposing the heating element,
and the heating element extends from the housing
toward the insulated contact in the bottom of the
outlet shell.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the outlet shell. These clips engage and hold the
heating element against the insulated contact long
enough for the resistor coil to heat up. When the
heating element is engaged with the contact, battery
current can flow through the resistor coil to ground,
causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the outlet shell, the protective heat
shield slides downward on the housing so that the
heating element is recessed and shielded around its
circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For complete circuit diagrams, refer toHorn/Ci-
gar Lighter/Power Outletin Wiring Diagrams.
(1) Check the fused B(+) fuse in the junction block.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fused B(+) fuse in
Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTIONWJ
POWER DISTRIBUTION (Continued)

REMOVAL
REMOVAL - CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled,
babbitt-lined bearings that are pressed into the cyl-
inder block and then line reamed. The camshaft
bearing bores and bearing diameters are not the
same size. They are stepped down in 0.254 mm
(0.010 inch) increments from the front bearing (larg-
est) to the rear bearing (smallest). This permits eas-
ier removal and installation of the camshaft. The
camshaft bearings are pressure lubricated. Camshaft
end play is maintained by the thrust plate.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Using Special tool 8544 Camshaft Bushing
Remover Installer, remove the camshaft bearings.
REMOVAL - CAMSHAFT
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Disconnect negative cable from battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL) and condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL), if
equipped with A/C.
(4) Remove the engine cylinder head cover (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(5) Remove the rocker arms, bridges and pivots
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL).
(6) Remove the push rods.
(7) Remove the engine cylinder head and gasket
(Refer to 9 - ENGINE/CYLINDER HEAD - REMOV-
AL).
(8) Remove the hydraulic valve tappets from the
engine cylinder block (Refer to 9 - ENGINE/ENGINE
BLOCK/HYDRAULIC LIFTERS (CAM IN BLOCK) -
REMOVAL).
(9) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(10) Remove the timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Rotate the crankshaft until the crankshaft
sprocket timing mark is aligned on centerline with
the camshaft sprocket timing mark (Fig. 32).
(12) Remove the timing chain and sprockets (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - REMOVAL).
(13) Remove the front bumper and/or grille, as
required.
(14) Remove the two thrust plate retaining screws,
thrust plate and camshaft (Fig. 31).
INSPECTION
INSPECTION - CAMSHAFT BEARINGS
(1) Inspect the bearing journals for uneven wear
pattern or finish.
(2) Inspect the bearings for wear.
INSPECTION - CAMSHAFT
(1) Inspect the cam lobes for wear.
(2) Inspect the camshaft position sensor drive gear
for wear.
(3) If the camshaft appears to have been rubbing
against the thrust washer, examine the oil pressure
Fig. 30 CamshaftÐTypical
1 - CAMSHAFT
2 - LOBES
3 - BEARING JOURNAL
WJENGINE - 4.0L 9 - 31
CAMSHAFT & BEARINGS (Continued)

(e) If end play is not within specification, inspect
crankshaft thrust faces for wear. If no wear is
apparent, replace the thrust bearing and measure
end play. If end play is still not within specifica-
tion, replace the crankshaft.
(11) If the crankshaft was removed, install the
crankshaft into the cylinder block.
(12) Install main bearing cap brace tighten nuts to
47 N´m (35 ft. lbs.) torque.
(13) Install oil pump assy. and tighten attaching
bolts to 23 N´m (17 ft. lbs.)
(14) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(15) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(16) Lower the vehicle.
(17) Install the spark plugs. Tighten the plugs to
37 N´m (27 ft. lbs.) torque.
(18) Fill the oil pan with engine oil to the full
mark on the dipstick level.
(19) Connect negative cable to battery.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
This procedure is done with the timing case cover
installed.
(1) Disconnect negative cable from battery.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(3) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(4) Remove the radiator shroud.
(5) Carefully remove the oil seal. Make sure seal
bore is clean.
INSTALLATION
This procedure is done with the timing case cover
installed.
(1) Position the replacement oil seal on Timing
Case Cover Alignment and Seal Installation Tool
6139 with seal open end facing inward. Apply a light
film of Perfect Seal, or equivalent, on the outside
diameter of the seal. Lightly coat the crankshaft with
engine oil.
(2) Position the tool and seal over the end of the
crankshaft and insert a draw screw tool into Seal
Installation Tool 6139 (Fig. 50). Tighten the nut
against the tool until it contacts the cover.
(3) Remove the tools. Apply a light film of engine
oil on the vibration damper hub contact surface of
the seal.
(4) Apply MopartSilicone Rubber Adhesive Seal-
ant to the keyway in the crankshaft and insert the
key. With the key inserted in the keyway in the
crankshaft, install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(5) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install the radiator shroud.
(7) Connect negative cable to battery.
Fig. 49 Crankshaft End Play Measurement
1 - DIAL INDICATOR
2 - CRANKSHAFT
Fig. 50 Timing Case Cover Oil Seal Installation
1 - SEAL INSTALLATION TOOL
2 - DRAW SCREW TOOL
WJENGINE - 4.0L 9 - 41
CRANKSHAFT MAIN BEARINGS (Continued)

ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DESCRIPTIONÐ4.7L ENGINE.............63
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........64
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........65
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............66
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION.............67
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE.............68
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......69
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........70
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........70
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........70
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............71
REMOVAL.............................71
INSTALLATION.........................73
SPECIFICATIONS
4.7L ENGINE.........................74
SPECIFICATIONS - 4.7L H.O. ENGINE.....77
TORQUE............................79
SPECIAL TOOLS
4.7L ENGINE.........................80
AIR CLEANER ELEMENT
REMOVAL - 4.7L........................83
INSTALLATION - 4.7L....................83
AIR CLEANER HOUSING
REMOVAL - 4.7L........................84
INSTALLATION - 4.7L....................84
CYLINDER HEAD - LEFT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........84
DESCRIPTION - VALVE GUIDES..........84
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................84
DIAGNOSIS AND TESTINGÐCYLINDER
HEAD GASKET.......................85
REMOVAL.............................85
CLEANING............................86
INSPECTION..........................87INSTALLATION.........................87
CAMSHAFT(S) - LEFT
DESCRIPTION.........................88
REMOVAL.............................89
INSTALLATION.........................90
CYLINDER HEAD COVER(S) - LEFT
DESCRIPTION.........................93
REMOVAL - LEFT SIDE..................93
CLEANING............................93
INSTALLATIONÐLEFT SIDE...............93
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................94
STANDARD PROCEDUREÐREFACING......94
REMOVAL.............................94
INSTALLATION.........................95
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION.........................96
REMOVAL.............................96
INSTALLATION.........................96
VALVE SPRINGS
DESCRIPTION.........................97
VALVE STEM SEALS
DESCRIPTION.........................97
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........97
DESCRIPTION - VALVE GUIDES..........97
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐCYLINDER
HEAD GASKET.......................97
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................98
REMOVAL.............................98
CLEANING............................99
INSPECTION..........................99
INSTALLATION.........................99
CAMSHAFT(S) - RIGHT
DESCRIPTION........................100
REMOVAL............................100
INSTALLATION........................102
CYLINDER HEAD COVER(S) - RIGHT
DESCRIPTION........................104
REMOVAL - RIGHT SIDE................104
CLEANING...........................104
INSTALLATION - RIGHT SIDE.............104
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................104
STANDARD PROCEDUREÐREFACING.....105
REMOVAL............................105
INSTALLATION........................106
WJENGINE - 4.7L 9 - 61

DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
FlexplateÐBolts 60 45 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick Tube to Engine
BlockÐBolt 15 Ð 130
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner
ArmÐSpecial
Pin Bolt 17 Ð 150
Hydraulic TensionerÐBolts 28 Ð 250
Timing Chain Primary
TensionerÐBolts28 Ð 250
Timing Drive Idler SprocketÐ
Bolt34 25 Ð
Thermostat HousingÐBolts 13 Ð 115
Water PumpÐBolts 54 40 ÐSPECIAL TOOLS
4.7L ENGINE
Spanner Wrench 6958
Adapter Pins 8346
Engine Lifting Studs 8400
Engine Lift Fixture 8347
9 - 80 ENGINE - 4.7LWJ
ENGINE - 4.7L (Continued)

(8) Remove radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bolt.
(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 62).
(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 63).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Using Special Tool 8348 and 8512, install
crankshaft front seal (Fig. 64).
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(3) Install radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(4) Install upper radiator hose.
(5) Install A/C compressor and tighten fasteners to
54 N´m (40 ft. lbs.).
(6) Install accessory drive belt refer (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).(7) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect negative cable to battery.
Fig. 62 Crankshaft DamperÐRemoval
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 63 Crankshaft Front SealÐRemoval
1 - SPECIAL TOOL 8511
Fig. 64 Crankshaft Front SealÐInstallation
1 - TIMING CHAIN COVER
2 - SPECIAL TOOL 8348
3 - SPECIAL TOOL 8512
9 - 116 ENGINE - 4.7LWJ
CRANKSHAFT OIL SEAL - FRONT (Continued)

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506 (Fig. 65), remove the
crankshaft rear oil seal.
INSTALLATION
(1) Position the magnetic seal guide Special Tool
8349±2 (Fig. 66) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.
(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle (Fig. 67),
with a hammer, tap the seal into place. Continue totap on the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) Install the transmission.
Fig. 65 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8506
Fig. 66 Crankshaft Rear Oil Seal Guide Special Tool
8349±2 and Oil
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349±2 GUIDE
Fig. 67 Crankshaft Rear Oil Seal Installation
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349±1 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
WJENGINE - 4.7L 9 - 117

(3) Remove crankshaft damper bolt.
(4) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 79).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512±A as follows, The
nut is threaded onto the shaft first. Then the roller
bearing is placed onto the threaded rod (The hard-
ened bearing surface of the bearingMUSTface the
nut). Then the hardened washer slides onto the
threaded rod (Fig. 80). Once assembled coat the
threaded rod's threads with MopartNickel Anti-
Seize or (Loctite No. 771).
(3) Using Special Tool 8512A, press damper onto
crankshaft (Fig. 81).
(4) Install then tighten crankshaft damper bolt to
175 N´m (130 ft. lbs.).(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Connect negative cable to battery.
Fig. 79 Crankshaft DamperÐRemoval
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 80 Proper Assembly Method for Special Tool
8512±A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 81 Crankshaft Damper Installation
1 - SPECIAL TOOL 8512A
WJENGINE - 4.7L 9 - 123
VIBRATION DAMPER (Continued)