2003 JEEP GRAND CHEROKEE Transmission pan bolt

INSTALLATION
A gear-type oil pump is mounted at the underside
of the cylinder block opposite the No.4 main bearing.
(1) Install the oil pump on the cylinder block using
a replacement gasket. Tighten the bolts to 23 N´m
(17 ft. lbs.) torque.
(2) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(3) Fill the oil pan with oil to the specified level.
INTAKE MANIFOLD
DESCRIPTION
The intake manifold (Fig. 83) is made of cast alu-
minum and uses eleven bolts to mount to the cylin-
der head. This mounting style improves sealing and
reduces the chance of leaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Disconnect the battery negative cable.
(2) Remove air cleaner inlet hose from the resona-
tor assembly.
(3) Remove the air cleaner assembly.
(4) Remove the throttle cable, vehicle speed control
cable (if equipped) and the transmission line pres-
sure cable (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - AW4/THROTTLE VALVE
CABLE - REMOVAL).
(5) Disconnect the following electrical connections
and secure their harness out of the way:
²Throttle Position Sensor
²Idle Air Control Motor
²Coolant Temperature Sensor (at thermostat
housing)
²Intake Air Temperature Sensor
²Oxygen Sensor
²Crank Position Sensor
²Six (6) Fuel Injector Connectors
²Manifold Absolute Pressure (MAP) Sensor.
(6) Disconnect HVAC, and Brake Booster vacuum
supply hoses at the intake manifold.
(7) Perform the fuel pressure release procedure.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(8) Disconnect and remove the fuel system supply
line from the fuel rail assembly.
(9) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(10) Remove the power steering pump from the
intake manifold and set aside.
(11) Raise the vehicle.
(12) Disconnect the exhaust pipes from the engine
exhaust manifolds.
(13) Lower the vehicle.
(14) Remove the intake manifold and exhaust
manifold bolts and manifolds (Fig. 84).
INSTALLATION
If the manifold is being replaced, ensure all the fit-
ting, etc. are transferred to the replacement mani-
fold.
(1) Install a new engine exhaust/intake manifold
gasket over the alignment dowels on the cylinder
head.
(2) Position the engine exhaust manifolds to the
cylinder head. Install fastener Number 3 and finger
tighten at this time (Fig. 84).
Fig. 83 Intake Manifold 4.0L Engine
WJENGINE - 4.0L 9 - 57
OIL PUMP (Continued)

(3) Install intake manifold on the cylinder head
dowels.
(4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 84).
(5) Install washer and fastener Numbers 6 and 7
(Fig. 84).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 84).
²Fastener Numbers 1 through 5ÐTighten to 33
N´m (24 ft. lbs.) torque.
²Fastener Numbers 6 and 7ÐTighten to 31 N´m
(23 ft. lbs.) torque.
²Fastener Numbers 8 through 11ÐTighten to 33
N´m (24 ft. lbs.) torque.
(7) Install the power steering pump to the intake
manifold.
(8) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the fuel system supply line to the fuel
rail assembly.
(10) Connect all electrical connections on the
intake manifold.
(11) Connect the vacuum hoses previously
removed.
(12) Install throttle cable, vehicle speed control
cable (if equipped).
(13) Install the transmission line pressure cable (if
equipped) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - AW4/THROTTLE VALVE
CABLE - INSTALLATION).
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the resonator assem-
bly.
(16) Raise the vehicle.
(17) Connect the exhaust pipes to the engine
exhaust manifolds. Tighten the bolts to 31 N´m (23
ft. lbs.)
(18) Lower the vehicle.(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust manifolds (Fig. 85) are log style
and are made of high silicon molybdenum cast iron.
The exhaust manifolds share a common gasket with
the intake manifold. The exhaust manifolds also
incorporate ball flange outlets for improved sealing
and strain free connections.
REMOVAL
The intake and engine exhaust manifolds on the
4.0L engine must be removed together. The manifolds
use a common gasket at the cylinder head.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - REMOVAL).
INSTALLATION
(1) The exhaust manifold and the intake manifold
must be installed together using a common gasket.
(2) (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - INSTALLATION).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) Remove the fan, hub assembly and fan shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL) (if equipped) and gen-
erator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 86).
INSTALLATION
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
Fig. 84 Intake and Exhaust Manifolds Installation
9 - 58 ENGINE - 4.0LWJ
INTAKE MANIFOLD (Continued)

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)

FLEX PLATE
REMOVAL
(1) Remove the transmission.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 60 N´m
(45 ft. lbs.) in the sequence shown (Fig. 68).
(3) Install the transmission.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pistons are made of a high strength aluminum
alloy. The anodized top ring groove and crown has
been replaced with a coated top ring that is blue in
color on the bottom surface. Piston skirts are coated
with a solid lubricant (Molykote) to reduce friction
and provide scuff resistance. The connecting rods are
made of forged powdered metal, with a ªfractured
capº design. A pressed fit piston pin is used to attach
the piston and connecting rod on the 4.7L. The 4.7L
HO uses a full floating piston pin.
STANDARD PROCEDUREÐPISTON FITTING
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm (
.0001 in.) INCREMENTS is required. If a bore gauge
is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at a point 38.0 mm (1.5 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then take
an additional bore reading 90 degrees to that at point
B (Fig. 70).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 69). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
(5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fit
with the cylinder bore.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components:
²Oil pan and gasket/windage tray (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
Fig. 68 Flexplate Tightening Sequence
1 - FLEXPLATE
Fig. 69 Moly Coated PistonÐTypical
1 - MOLY COATED
2 - MOLY COATED
9 - 118 ENGINE - 4.7LWJ

STRUCTURAL COVER
DESCRIPTION
The structural dust cover is made of die cast alu-
minum and joins the lower half of the transmission
bell housing to the engine bedplate.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from
exhaust manifold.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 82) in the sequence shown.
(5) Pivot the exhaust pipe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 83) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 83) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
FRONT MOUNT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the engine oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER - REMOVAL).
(3) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
Fig. 82 Structural Cover
Fig. 83 Structural Cover
9 - 124 ENGINE - 4.7LWJ

ITEM DESCRIPTION TORQUE
1 NUT 45 N´m
(Qty 1) (33 ft. lbs)
2 BOLT 46 N´m
(Qty 4) (34 ft. lbs.)
3 BOLT 68 N´m
(Qty 2 Per
Side)(50 ft. lbs.)
4 BOLT 46 N´m
(Qty 2 Per
Side)(34 ft. lbs.)
5 BOLT 46 N´m
(Qty 4) (34 ft. lbs.)
INSTALLATION
(1) Position the insulator mount and install the
through bolt.
(2) Lower the transmission enough to install the
four insulator-to-transmission mounting bolts. Torque
the bolts to 46N´m (34 ft. lbs.).
(3) Install the through bolt lock nut. Torque nut to
68N´m (50 ft. lbs.).
(4) Remove jack, lower vehicle.
LUBRICATION
DESCRIPTION
The lubrication system (Fig. 88) is a full flow fil-
tration pressure feed type.
OPERATION
Oil from the oil pan is pumped by a gerotor type oil
pump directly mounted to the crankshaft nose. Oil
pressure is controlled by a relief valve mounted
inside the oil pump housing. For lubrication flow
refer to (Fig. 88).
The camshaft exhaust valve lobes and rocker arms
are lubricated through a small hole in the rocker
arm; oil flows through the lash adjuster then through
the rocker arm and onto the camshaft lobe. Due to
the orentation of the rocker arm, the camshaft intake
lobes are not lubed in the same manner as the
exhaust lobes. The intake lobes are lubed through
internal passages in the camshaft. Oil flows through
a bore in the number 3 camshaft bearing bore, and
as the camshaft turns, a hole in the camshaft aligns
with the hole in the camshaft bore allowing engine
oil to enter the camshaft tube. The oil then exits
through 1.6mm (0.063 in.) holes drilled into the
intake lobes, lubricating the lobes and the rocker
arms.
Fig. 86 Engine Rear MountÐ4X2
Fig. 87 Engine Rear MountÐ4X4
9 - 126 ENGINE - 4.7LWJ
REAR MOUNT (Continued)

(5) With a wiping cloth, clean the gasket sealing
surface of oil and grime.
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 94)hand
tighten filter one full turn, do not over tighten.
(3) Add oil, verify crankcase oil level and start
engine. Inspect for oil leaks.
OIL PAN
DESCRIPTION
The engine oil pan is made of laminated steel and
has a single plane sealing surface. The sandwich
style oil pan gasket has an integrated windage tray
and steel carrier. The sealing area of the gasket is
molded with rubber and is designed to be reused as
long as the gasket is not cut, torn or ripped.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove structural cover (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - REMOV-
AL).
(4) Remove exhaust system Y-pipe.
(5) Remove starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
(6) Drain engine oil.
(7) Un-clip transmission lines from support on oil
pan stud. Move lines for oil pan clearance.
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when lowering oil pan.
Gasket can not be removed with oil pan.
(8) Remove oil pan bolts and oil pan.
(9) Remove oil pump pickup tube.
(10) Remove oil pan gasket.
CLEANING
(1) Clean oil pan in solvent and wipe dry with a
clean cloth.
(2) Clean the oil pan gasket surface.DO NOTuse
a grinder wheel or other abrasive tool to clean seal-
ing surface.
(3) Clean oil screen and tube thoroughly in clean
solvent.
INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads. Repair as necessary.
(2) Inspect the oil pan mounting flange for bends
or distortion. Straighten flange, if necessary.
INSTALLATION
(1) Clean oil pan and all sealing surfaces. Inspect
oil pan gasket and replace as necessary.
(2) Install oil pan gasket.
Fig. 93 Oil Filter - 4.7L Engine
1 - ENGINE OIL FILTER
Fig. 94 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 132 ENGINE - 4.7LWJ
OIL FILTER (Continued)

NOTE: When installing oil pan gasket/windage tray,
start four pan bolts at each corner before tightening
oil pickup tube. This will keep pan gasket in align-
ment.
(3) Install oil pump pick-up tube using a new
O-ring. First tighten bolt at O-ring end of tube to 28
N´m (20 ft. lbs.). Tighten remain tube support fasten-
ers to 28 N´m (20 ft. lbs.).
(4) Install oil pan and tighten fasteners to 15 N´m
(11 ft. lbs.) (Fig. 95).
(5) Reconnect transmission oil cooler lines to oil
pan stud bolt.
(6) Install starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - INSTALLATION).
(7) Install exhaust system Y-pipe.
(8) Install structural cover (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION).
(9) Lower vehicle.
(10) Fill engine with proper amount of oil (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
(11) Connect negative cable to battery.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, solid-state engine oil pressure sensor
(sending unit) is located in an engine oil pressure
gallery.
OPERATION
The oil pressure sensor uses three circuits. They are:
²A 5±volt power supply from the Powertrain Con-
trol Module (PCM)
²A sensor ground through the PCM's sensor
return
²
A signal to the PCM relating to engine oil pressure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5±volt supply is sent to the sensor from the PCM
to power up the sensor. The sensor returns a voltage
signal back to the PCM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
instrument panel on either a CCD or PCI bus circuit
(depending on vehicle line) to operate the oil pressure
gauge and the check gauges lamp. Ground for the
sensor is provided by the PCM through a low-noise
sensor return.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Remove front splash shield.
(4) Disconnect oil pressure sender wire (Fig. 96).
(5) Remove the pressure sender (Fig. 96).
INSTALLATION
(1) Install oil pressure sender.
(2) Connect oil pressure sender wire.
(3) Install front splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
Fig. 95 Oil Pan Tightening Sequence
Fig. 96 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
WJENGINE - 4.7L 9 - 133
OIL PAN (Continued)