2003 JEEP GRAND CHEROKEE fasteners

PDC LOWER COVER INSTALLATION
(1) Align the PDC housing lower cover on the bot-
tom of the PDC.
(2) Evenly press the lower cover into place until
latches are fully engaged.
(3) Where the right headlamp and dash harness
enters the PDC, tape the harness securely to the
trough formation on the PDC lower cover.
(4) Install the PDC in its mounting location on the
battery support.
(5) Install the battery wire harness over the two
PDC B+ terminal studs. Torque the nuts to 11.3 N´m
(100 in. lbs.).
(6) Install the battery. Refer to Battery System for
the procedure.
(7) Install the PDC cover.
INSTALLATION
The Power Distribution Center (PDC) main hous-
ing unit, the PDC fuse wedges and the PDC bus bars
cannot be repaired and are only serviced as a unit
with the right headlamp and dash wire harness. If
the PDC main housing unit, the fuse wedges or the
bus bars are faulty or damaged, the entire PDC and
right headlamp and dash wire harness unit must be
replaced.
(1) Position the PDC and the right headlamp and
dash wire harness unit in the engine compartment.
(2) Engage the PDC housing mounts with the
stanchions of the battery support and push the unit
downward until the mount latches fully engage the
mounting tabs on the stanchions.
(3) Install the two-holed eyelet of the battery wire
harness PDC take outs onto the two PDC B(+) termi-
nal studs.
(4) Install and tighten the nuts that secure the
eyelet of the battery wire harness PDC take outs to
the B(+) terminal studs. Tighten the nuts to 11.3
N´m (100 in. lbs.).
(5) Engage each of the retainers that secure the
right headlamp and dash wire harness to the vehicle
body and chassis components. Refer toConnector
Locationsin Wiring Diagrams for the location of
more information on the right headlamp and dash
wire harness retainer locations.
(6) Install all of the fasteners that secure each of
the right headlamp and dash wire harness ground
eyelets to the vehicle body and chassis components.
Refer toConnector Locationsin Wiring Diagrams
for the location of more information on the ground
eyelet locations.
(7) Reconnect each of the right headlamp and dash
wire harness connectors. Refer toConnector Loca-
tionsin Wiring Diagrams for the location of more
information on the right headlamp and dash wire
harness connector locations. For connectors securedwith screws, tighten the screws to 4.3 N´m (38 in.
lbs.).
(8) Reconnect the battery negative cable.
POWER OUTLET
DESCRIPTION - FRONT POWER OUTLET
An accessory power outlet is standard equipment
on this model. The power 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 power outlet base is secured by a snap fit within
the center lower bezel. A hinged door with an over-
center spring flips closed to conceal and protect the
power outlet base when the power outlet is not being
used, and flips open below the center lower bezel
while the power outlet is in use.
The power outlet receptacle unit and the power
outlet door are each available for service replace-
ment.
OPERATION - FRONT POWER OUTLET
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet receives battery voltage from a fuse
in the junction block at all times.
While the power outlet is very similar to a cigar
lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the recepta-
cle shell that are used to secure the cigar lighter
heating element to the insulated contact.
DIAGNOSIS AND TESTING - POWER OUTLET
For complete circuit diagrams, refer toHorn/Ci-
gar Lighter/Power Outletin Wiring Diagrams.
WARNING: REFER TO RESTRAINTS BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(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) Check for battery voltage at the fused B(+) fuse
in the junction block. If OK, go to Step 3. If not OK,
repair the open fused B(+) circuit to the Power Dis-
tribution Center (PDC) fuse as required.
(3) Open the power outlet door. Check for continu-
ity between the inside circumference of the power
8W - 97 - 12 8W-97 POWER DISTRIBUTIONWJ
POWER DISTRIBUTION CENTER (Continued)

DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Transmission Support Bracket
ÐBolt (Manual) 46 34 Ð
Transmission Support Bracket/
CushionÐBolt (4WD Auto) 75 55 Ð
Transmission Support Adaptor
BracketÐBolts (2WD Auto) 75 55 Ð
Exhaust Manifold/PipeÐNuts 27 20 Ð
Intake/Exhaust Manifold
Fasteners #1-5 33 24 Ð
Fasteners #6 and 7 14 Ð 126
Fasteners #8-11 33 24 Ð
Flywheel to Converter
HousingÐBolts38 28 Ð
Flywheel to CrankshaftÐBolts 143 105 Ð
Front Cover to BlockÐBolts
1/4-20 7 Ð 60
5/16-18 22 Ð 192
Fuel RailÐBolts/Stud 12 Ð 108
GeneratorÐBolts 57 42 Ð
Generator Bracket to EngineÐ
Bolts47 35 Ð
Idler Pulley to Cylinder
HeadÐBolt47 35 Ð
Main Bearing CapÐBolts 108 80 Ð
Oil Filter 18 Ð 156
Oil Filter Connector to
Adaptor 47 35 Ð
Block 68 50 Ð
Adaptor Bolts 102 50 Ð
Oil GalleyÐPlug 41 30 Ð
Oil PanÐBolts
1/4-20 9.5 Ð 84
5/16-18 15 Ð 132
Oil PanÐDrain Plug 34 25 Ð
Oil Pump
Mounting Bolts 23 Ð 204
Cover Bolts 8 Ð 70
Rocker Arm Assembly to
Cylinder
HeadÐCapscrews 30 21 Ð
Spark Plugs 37 27 ÐDESCRIPTION N´m Ft. In.
Lbs. Lbs.
Starter MotorÐMounting Bolts 45 33 Ð
Thermostat HousingÐBolts 18 Ð 156
Throttle BodyÐBolts 10 Ð 90
Vibration DamperÐBolt 108 80 Ð
Water Pump to BlockÐBolts 23 17 Ð
AIR CLEANER ELEMENT
REMOVAL - 4.0L
(1) Unlatch four clips retaining air cleaner cover to
air cleaner housing (Fig. 6).
Fig. 6 Air Cleaner Assembly Ð4.0L Engine
1 - RESONATOR BOLTS
2 - CLAMPS
3 - AIR DUCT
4 - AIR CLEANER COVER
5 - CLIPS
6 - HOUSING
7 - HOUSING BOLTS (3)
8 - LOWER HOUSING NUTS (3)
9 - RESONATOR
9 - 18 ENGINE - 4.0LWJ
ENGINE - 4.0L (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)

CONDITION POSSIBLE CAUSES CORRECTIONS
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.7. Tighten to correct torque
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal, damaged
or misaligned.5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL).
6. Scratched or damaged vibration
damper hub.6. Polish or replace damper.
WJENGINE - 4.7L 9 - 67
ENGINE - 4.7L (Continued)

CYLINDER HEAD COVER(S) -
LEFT
DESCRIPTION
The cylinder head covers are made of die cast mag-
nesium, and are not interchangeable from side-to-
side. It is imperative that nothing rest on the
cylinder head covers. Prolonged contact with other
items may wear a hole in the cylinder head cover.
REMOVAL - LEFT SIDE
(1) Disconnect negative cable from battery.
(2) Remove the resonator assemble and air inlet
hose.
(3) Disconnect injector connectors and un-clip the
injector harness.
(4) Route injector harness in front of cylinder head
cover.
(5) Disconnect the left side breather tube and
remove the breather tube.(6) Remove the cylinder head cover mounting
bolts.
(7) Remove cylinder head cover and gasket.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSTALLATIONÐLEFT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the cylin-
der head cover. Prolonged contact with other
objects may wear a hole in the engine cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Install cylinder head cover and hand start all
fasteners. Verify that all studs are in the correct loca-
tion shown in (Fig. 22).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs.).
(4) Install left side breather and connect breather
tube.
(5) Connect injector electrical connectors and injec-
tor harness retaining clips.
(6) Install the resonator and air inlet hose.
(7) Connect negative cable to battery.
Fig. 21 Tightening Left Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
Fig. 22 Cylinder Head CoverÐLeft
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
WJENGINE - 4.7L 9 - 93
CAMSHAFT(S) - LEFT (Continued)

CYLINDER HEAD COVER(S) -
RIGHT
DESCRIPTION
The cylinder head covers are made of die cast mag-
nesium, and are not interchangeable from side-to-
side. It is imperative that nothing rest on the
cylinder head covers. Prolonged contact with other
items may wear a hole in the cylinder head cover.
REMOVAL - RIGHT SIDE
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
(8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube.
(10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
(12) Remove cylinder head cover retaining bolts.
(13) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSTALLATION - RIGHT SIDE
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.(2) Install cylinder head cover and hand start all
fasteners. Verify that all double ended studs are in
the correct location shown in (Fig. 38).
(3) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs).
(4) Install right rear breather tube and filter
assembly.
(5) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(6) Install the oil fill tube.
(7) Install PCV hose.
(8) Install heater hoses.
(9) Install air conditioning compressor retaining
bolts.
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Fill Cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(13) Connect battery negative cable.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. Each
valve is actuated by a roller rocker arm which pivots
on a stationary lash adjuster. All valves use three
bead lock keepers to retain the springs and promote
valve rotation.
Fig. 38 Cylinder Head CoverÐRight
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 N´m (105 in. lbs.)
9 - 104 ENGINE - 4.7LWJ

CRANKSHAFT MAIN BEARING SELECTION
The main bearings are ªselect fitº to achieve proper
oil clearances. For main bearing selection, the crank-
shaft position sensor target wheel has grade identifi-
cation marks stamped into it (Fig. 60). These marks
are read from left to right, corresponding with jour-
nal number 1, 2, 3, 4 and 5. The crankshaft position
sensor target wheel is mounted to the number 8
counter weight on the crankshaft.
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHARTÐ4.7L
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A0.008 mm
U/S63.488±63.496 mm
(0.0004 in.)
U/S(2.4996±2.4999 in.)
BNOMINAL 63.496±63.504 mm
(2.4999±2.5002 in.)
C0.008 mm
O/S63.504±63.512 mm
(0.0004 in.)
O/S(2.5002±2.5005 in.)
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 61).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove A/C compressor mouning fasteners and
set aside.
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove upper radiator hose.
(6) Disconnect electrical connector for fan mounted
inside radiator shroud.
(7) Remove radiator shroud attaching fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
Fig. 60 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 61 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
WJENGINE - 4.7L 9 - 115
CRANKSHAFT MAIN BEARINGS (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)