2003 JEEP GRAND CHEROKEE crank case vent

(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)

INTAKE MANIFOLD
DESCRIPTION
The intake manifold is made of a composite mate-
rial and features long runners which maximizes low
end torque. The intake manifold uses single plane
sealing which consist of eight individual press in
place port gaskets to prevent leaks. Eight studs and
two bolts are used to fasten the intake to the head.
DIAGNOSIS AND TESTINGÐINTAKE
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
(1) Disconnect negative cable from battery.
(2) Remove air cleaner housing and throttle body
resonator (Fig. 104).
(3) Disconnect throttle and speed control cables.
(4) Disconnect electrical connectors for the follow-
ing components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Disconnect vapor purge hose, brake booster
hose, speed control servo hose, positive crankcase
ventilation (PCV) hose.
Fig. 102 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 103 Oil Pump and Primary Timing Chain
Tensioner Tightening Sequence
Fig. 104 Throttle Body Resonator
1 - THROTTLE BODY RESONATOR
2 - BOLT
3 - BOLT
9 - 136 ENGINE - 4.7LWJ
OIL PUMP (Continued)

(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(9) Install ignition coil towers (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/IGNITION COIL -
INSTALLATION).
(10) Install coolant temperature sensor (Refer to 7
- COOLING/ENGINE/ENGINE COOLANT TEMP
SENSOR - INSTALLATION).
(11) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(12) Install top oil dipstick tube retaining bolt and
ground strap.
(13) Install right side engine lifting stud.
(14) Install generator including electrical connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - INSTALLATION).
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Install air conditioning compressor including
electrical connections.
(17) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(18) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(19) Install cowl to hood seal (Refer to 23 - BODY/
WEATHERSTRIP/SEALS/COWL WEATHERSTRIP -
INSTALLATION).
(20) Install air cleaner housing and throttle body
resonator. Tighten resonator bolts 4.5 N´m (40 in.
lbs.).
(21) Connect negative cable to battery.
EXHAUST MANIFOLD - LEFT
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nutthat is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
(1) Disconnect negative cable for battery.
(2) Hoist vehicle.
(3) Disconnect exhaust pipe at manifold.
(4) Lower vehicle.
(5) Remove air cleaner housing and tube.
(6) Remove the front two exhaust heat shield
retaining fasteners. Raise vehicle and remove the
fasteners at rear of heat shield.
(7) Remove heat shield (Fig. 107).
(8) Lower vehicle and remove the upper exhaust
manifold retaining bolts (Fig. 107).
(9) Raise vehicle and remove the lower exhaust
manifold retaining bolts (Fig. 107).
(10) Remove exhaust manifold and gasket (Fig.
107). Manifold is removed from below the engine
compartment.
CLEANING
(1) Clean the exhaust manifold using a suitable
cleaning solvent, then allow to air dry.
(2) Clean all gasket residue from the manifold
mating surface.
INSPECTION
(1) Inspect the exhaust manifold for cracks in the
mating surface and at every mounting bolt hole.
(2) Using a straight edge and a feeler gauge, check
the mating surface for warp and twist.
(3) Inspect the manifold to exhaust pipe mating
surface for cracks, gouges, or other damage that
would prevent sealing.
INSTALLATION
(1) Install exhaust manifold and gasket from below
engine compartment.
(2) Install lower exhaust manifold fasteners (Fig.
107). DO NOT tighten until all fasteners are in
place.
(3) Lower vehicle and install upper exhaust mani-
fold fasteners (Fig. 107). Tighten all manifold bolts
starting at center and working outward to 25 N´m
(18 ft. lbs.).
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(4) Install exhaust manifold heat shield (Fig. 107).
Tighten fasteners to 8 N´m (72 in. lbs.), then loosen
45 degrees.
(5) Install air cleaner housing and tube.
(6) Connect exhaust pipe to manifold.
(7) Connect negative cable to battery.
9 - 138 ENGINE - 4.7LWJ
INTAKE MANIFOLD (Continued)

(8) Inspect system body grounds for loose or dirty
connections. Refer to Group 8, Wiring for ground
locations.
(9) Verify crankcase ventilation (CCV) operation.
Refer to Emission Control System for additional
information.
(10) Inspect all fuel line quick-connect fittings for
damage or leaks.
(11) Verify hose connections to all ports of vacuum
fittings on intake manifold, and for emission system
are tight and not leaking.
(12) Inspect accelerator cable, transmission throt-
tle cable (if equipped) and speed control cable connec-
tions (if equipped). Check their connections to
throttle body linkage for any binding or restrictions.
(13) Verify vacuum booster hose is firmly con-
nected to fitting on intake manifold. Also check con-
nection to brake vacuum booster.(14) Inspect air cleaner inlet and air cleaner ele-
ment for dirt or restrictions.
(15) Inspect radiator grille area, radiator fins and
air conditioning condenser for restrictions.
(16) 4.0L Engine: Verify MAP, Intake Manifold Air
Temperature (IAT) sensor, TPS and Idle Air Control
(IAC) motor connectors are firmly connected (Fig. 9).
Be sure throttle body mounting bolts (Fig. 9)are
tight.
(17) 4.7L Engine: Verify Intake Manifold Air Tem-
perature (IAT) sensor, TPS and Idle Air Control (IAC)
motor connectors are firmly connected (Fig. 10). Be
sure throttle body mounting bolts (Fig. 10)are tight.
Fig. 8 Crankshaft Position SensorÐ4.7L V-8 Engine
1 - CRANKSHAFT POSITION SENSOR
2-STARTER
3 - ELEC. CONNECTOR
Fig. 9 IAT, MAP, IAC, TPS Sensor LocationsÐ4.0L
Engine
1 - MOUNTING BOLTS (4)
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.
14 - 34 FUEL INJECTIONWJ
FUEL INJECTION (Continued)

REMOVAL
The overdrive unit can be removed and serviced
separately. It is not necessary to remove the entire
transmission assembly to perform overdrive unit
repairs.
If only the overdrive unit requires service, refer to
Overdrive Removal for proper procedures.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.
(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary
exhaust components.
(3) Disconnect fluid cooler lines at transmission.
(4) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(5) Disconnect and remove crankshaft position sen-
sor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain sensor attaching bolts.
CAUTION: The crankshaft position sensor will be
damaged if the transmission is removed, or
installed, while the sensor is still bolted to the
engine block, or transmission (4.0L only). To avoid
damage, be sure to remove the sensor before
removing the transmission.
(6) Remove the bolts holding the bell housing
brace to the transmission.
(7) Remove nut holding the bell housing brace to
the engine to transmission bending brace.
(8) Remove the bell housing brace from the trans-
mission (Fig. 13).
(9) Remove the bolt holding the torque converter
cover to the transmission.
(10) Remove the torque converter cover from the
transmission.
(11) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(12) Remove fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On4x4
models, it will also be necessary to remove bolt
attaching transfer case vent tube to converter hous-
ing.
(13) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.(14) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts.
(15) Disconnect wires from park/neutral position
switch and transmission solenoid.
(16) Disconnect gearshift cable from transmission
manual valve lever (Fig. 14).
Fig. 13 Bell Housing Brace and Converter Cover
1 - Transmission
2 - Torque Converter Cover
3 - Bellhousing Brace
Fig. 14 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
WJAUTOMATIC TRANSMISSION - 42RE 21 - 27
AUTOMATIC TRANSMISSION - 42RE (Continued)

PRESSURE TEST
Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)Closed throttle 372-414 kPa (54-60 psi).
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 31 - 270
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Switch, park/neutral 34 25 -
Bolt, fluid pan 17 13 -
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, speedometer adapter 11 - 100
Screw, vehicle speed sensor 2.5 - 21
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
21 - 56 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

simultaneous movement without causing the trans-
mission throttle lever to either move ahead of, or lag
behind the lever on the throttle body.
ADJUSTMENT VERIFICATION
(1) Turn ignition key to OFF position.
(2) Remove air cleaner.
(3) Verify that lever on throttle body (Fig. 242) is
at curb idle position. Then verify that the transmis-
sion throttle lever (Fig. 243) is also at idle (fully for-
ward) position.
(4) Slide cable off attachment stud on throttle body
lever.
(5) Compare position of cable end to attachment
stud on throttle body lever:
²Cable end and attachment stud should be
aligned (or centered on one another) to within 1 mm
(0.039 in.) in either direction (Fig. 244).
²If cable end and attachment stud are misaligned
(off center), cable will have to be adjusted as
described in Throttle Valve Cable Adjustment proce-
dure.
(6) Reconnect cable end to attachment stud. Then
with aid of a helper, observe movement of transmis-
sion throttle lever and lever on throttle body.
²If both levers move simultaneously from idle to
half-throttle and back to idle position, adjustment is
correct.
²If transmission throttle lever moves ahead of, or
lags behind throttle body lever, cable adjustment will
be necessary. Or, if throttle body lever prevents
transmission lever from returning to closed position,
cable adjustment will be necessary.
ADJUSTMENT PROCEDURE
(1) Turn ignition switch to OFF position.
(2) Remove air cleaner if necessary.
(3) Disconnect cable end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Verify that transmission throttle lever is in
fully closed position. Then be sure lever on throttle
body is at curb idle position.
(5) Pry the T.V. cable lock (A) into the UP position
(Fig. 244). This will unlock the cable and allow for
readjustment.
(6) Apply just enough tension on the T.V. cable (B)
to remove any slack in the cable.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment.Slide the
sheath of the T.V. cable (D) back and forth until the
centerlines of the T.V. cable end (B) and the throttle
bell crank lever (C) are aligned within one millimeter
(1mm) (Fig. 244).
(7) While holding the T.V. cable in the set position
push the T.V. cable lock (A) into the down position
(Fig. 244). This will lock the present T.V. cable
adjustment.
Fig. 242 Throttle Valve Cable
1 - THROTTLE VALVE CABLE
2 - THROTTLE VALVE LEVER
3 - THROTTLE BODYFig. 243 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
2 - THROTTLE VALVE CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(S)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
WJAUTOMATIC TRANSMISSION - 42RE 21 - 127
THROTTLE VALVE CABLE (Continued)

(5) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(6) Check converter seating with steel scale and
straightedge (Fig. 52). Surface of converter lugs
should be at least 13 mm (1/2 in.) to rear of straight-
edge when converter is fully seated.
(7) Temporarily secure converter with C-clamp.
(8) Position transmission on jack and secure it
with chains.
(9) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Apply a light coating of MopartHigh Temp
Grease to the torque converter hub pocket in the rear
pocket of the engine's crankshaft.
(11) Raise transmission and align the torque con-
verter with the drive plate and the transmission con-
verter housing with the engine block.
(12) Move transmission forward. Then raise, lower,
or tilt transmission to align the converter housing
with the engine block dowels.
(13) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft. Verify that no wires, or the transmission
vent hose, have become trapped between the engine
block and the transmission.
(14) Install two bolts to attach the transmission to
the engine.(15) Install remaining torque converter housing to
engine bolts. Tighten to 68 N´m (50 ft.lbs.).
(16) Install rear transmission crossmember.
Tighten crossmember to frame bolts to 68 N´m (50
ft.lbs.).
(17) Install rear support to transmission. Tighten
bolts to 47 N´m (35 ft.lbs.).
(18) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member. Tighten clevis bracket to crossmember bolts
to 47 N´m (35 ft.lbs.). Tighten the clevis bracket to
rear support bolt to 68 N´m (50 ft.lbs.).
(19) Remove engine support fixture.
(20) Install new plastic retainer grommet on any
shift cable that was disconnected. Grommets should
not be reused. Use pry tool to remove rod from grom-
met and cut away old grommet. Use pliers to snap
new grommet into cable and to snap grommet onto
lever.
(21) Connect gearshift cable to transmission.
(22) Connect wires to solenoid and pressure switch
assembly connector, input and output speed sensors,
and line pressure sensor. Be sure transmission har-
nesses are properly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(23) Install all torque converter-to-driveplate bolts
by hand.
(24) Verify that the torque converter is pulled
flush to the driveplate. Tighten bolts to 31 N´m (270
in. lbs.).
(25) Install starter motor and cooler line bracket.
(26) Connect cooler lines to transmission.
(27) Install transmission fill tube.
(28) Install exhaust components.
(29) Install transfer case. Tighten transfer case
nuts to 35 N´m (26 ft.lbs.).
(30) Install the transfer case shift cable to the
cable support bracket and the transfer case shift
lever.
(31) Install the transmission collar onto the trans-
mission and the engine. Tighten the bolts to 54 N´m
(40 ft.lbs.).
(32) Align and connect propeller shaft(s).
(33) Adjust gearshift cable if necessary.
(34) Lower vehicle.
(35) Fill transmission with MopartATF +4, type
9602, Automatic Transmission fluid.
Fig. 52 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 198 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)