2003 JEEP GRAND CHEROKEE pump - standard procedure

INLET FILTER
REMOVAL
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 42). The fuel
pump module is located on top of fuel tank.
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 42). The fuel
pump module is located on top of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove filter by prying from bottom of module
with 2 screwdrivers. Filter is snapped to module.
(4) Clean bottom of pump module.
INSTALLATION
The fuel pump inlet filter (strainer) is located on
the bottom of fuel pump module (Fig. 42). The fuel
pump module is located on top of fuel tank.
(1) Snap new filter to bottom of module.
(2) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
QUICK CONNECT FITTING
DESCRIPTION
Different types of quick-connect fittings are used to
attach various fuel system components, lines and tubes.
These are: a single-tab type, a two-tab type or a plastic
retainer ring type. Some are equipped with safety latch
clips. Some may require the use of a special tool for dis-
connection and removal. Refer to Quick-Connect Fit-
tings Removal/Installation for more information.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Also refer to Fuel Tubes/Lines/Hoses and Clamps.
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Safety latch clips are
used on certain components/lines. Certain fittings
may require use of a special tool for disconnection.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure.
(2) Disconnect negative battery cable from battery.
(3) Clean fitting of any foreign material before dis-
assembly.
(4)2±Button Type Fitting:This type of fitting is
equipped with a push-button located on each side of
quick-connect fitting (Fig. 43). Press on both buttons
simultaneously for removal. Special tools are not
required for disconnection.
Fig. 42 Fuel Pump Inlet Filter
1 - FUEL PUMP MODULE
2 - FUEL PUMP INLET FILTER
WJFUEL DELIVERY 14 - 27

(9) Fill the power steering pump (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 1 Recirculating Ball Type Gear
1 - ADJUSTER NUT
2 - COVER
3 - PITMAN SHAFT
4 - O-RING
5 - BEARING
6 - GEAR HOUSING
7 - RACK PISTON
8 - RETAINING RING
9 - O-RING
10 - BEARING
11 - STUB SHAFT HOUSING
12 - PITMAN SHAFT SEAL
13 - PLASTIC BACKUP WASHER
14 - METAL BACKUP WASHER
15 - RETAINING RING
16 - DUST SEAL
Fig. 2 Pressure And Return Lines
1 - PRESSURE LINE
2 - RETURN LINE
3 - COUPLER BOLT
4 - STEERING GEAR
Fig. 3 Steering Gear Mounting
1 - MOUNTING BOLTS
2 - PITMAN SHAFT
3 - STABILIZER BAR
WJGEAR 19 - 17
GEAR (Continued)

INSTALLATION
(1) Lubricate new o-ring and teflon rings with
power steering fluid and install on the rack piston/
valve assembly.
(2) Lubricate the rack piston/valve assembly with
power steering fluid.
(3) Slide the assembly into the gear housing.
(4) Install new stub shaft housing o-rings and
install the housing. Tighten the housing bolts to 62
N´m (46 ft. lbs.).
(5) Install new o-ring on the pitman shaft cover.
(6) Install the pitman shaft into the gear housing.
(7) Install the pitman shaft cover bolts and tighten
to 62 N´m (46 ft. lbs.).
(8) Perform over-center rotation torque adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS)..
(9) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(10) Fill the power steering pump (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
STUB SHAFT HOUSING
REMOVAL
NOTE: If stub shaft housing, seal or bearing is dam-
aged the housing must be replaced.
(1) Remove the steering gear (Refer to 19 -
STEERING/GEAR - REMOVAL).
(2) Remove stub shaft housing bolts (Fig. 19).
(3) Remove housing from the steering gear (Fig.
20).
(4) Remove stub shaft housing o-rings (Fig. 15).
INSTALLATION
NOTE: If stub shaft housing, seal or bearing is dam-
aged the housing must be replaced.
(1) Grease stub shaft seal withspecial grease-
supplied with new stub shaft housing.
(2) Install new stub shaft housing o-rings.
(3) Install housing on the steering gear.
(4) Install the housing bolts and tighten to 62 N´m
( 46 ft. lbs.).
(5) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(6) Fill the power steering pump (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 19 Stub Shaft Housing
1 - STUB SHAFT HOUSING
2 - BOLTS
3 - STUB SHAFT
Fig. 20 Housing Removal
1 - STEERING GEAR
2 - HOUSING
WJGEAR 19 - 25
RACK PISTON/VALVE ASSEMBLY (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION - 4.0L, 4.7L................32
OPERATION
OPERATION - 4.7L....................32
OPERATION - 4.0L....................32
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 33
STANDARD PROCEDURE
STANDARD PROCEDURE - INITIAL
OPERATION - 4.0L....................33
STANDARD PROCEDURE - INITIAL
OPERATION - 4.7L....................33
REMOVAL
REMOVAL - 4.0L ENGINE...............34
REMOVAL - 4.7L ENGINE...............34
INSTALLATION
INSTALLATION - 4.0L ENGINE...........34
INSTALLATION - 4.7L ENGINE...........34
SPECIFICATIONS
TORQUE CHART......................35
SPECIAL TOOLS
POWER STEERING PUMP..............36
FLUID COOLER
DESCRIPTION.........................36
REMOVAL.............................36
INSTALLATION.........................37
HOSES - 4.0L
DESCRIPTION
DESCRIPTION - PRESSURE LINE........37
DESCRIPTION - RETURN LINE...........37
OPERATION
OPERATION - PRESSURE LINE..........37
OPERATION - RETURN LINE............37
REMOVAL.............................37
INSTALLATION.........................37
HOSES - 4.7L
DESCRIPTION
DESCRIPTION - 1/2º PRESSURE HOSE....38DESCRIPTION - 1/2º RETURN HOSE......38
DESCRIPTION - 3/8º PRESSURE HOSE....38
DESCRIPTION - 3/8º GEAR OUTLET HOSE . 38
DESCRIPTION - 3/8º RETURN HOSE......38
OPERATION
OPERATION - 1/2º PRESSURE HOSE......38
OPERATION - 1/2º RETURN HOSE........38
OPERATION - 3/8º PRESSURE HOSE......39
OPERATION - 3/8º GEAR OUTLET HOSE . . . 39
OPERATION - 3/8ºRETURN HOSE........39
REMOVAL
REMOVAL - 1/29PRESSURE HOSE.......39
REMOVAL - 1/29RETURN HOSE..........39
REMOVAL - 3/89PRESSURE HOSE.......39
REMOVAL - 3/89RETURN HOSE..........39
REMOVAL - 3/89GEAR OUTLET HOSE.....40
REMOVAL - INLET COOLER HOSE........40
REMOVAL - OUTLET COOLER HOSE......40
INSTALLATION
INSTALLATION - 1/29PRESSURE HOSE....40
INSTALLATION - 1/29RETURN HOSE......40
INSTALLATION - 3/89PRESSURE HOSE....41
INSTALLATION - 3/89RETURN HOSE......41
INSTALLATION - 3/89GEAR OUTLET HOSE . 41
INSTALLATION - INLET COOLER HOSE....41
INSTALLATION - OUTLET COOLER HOSE . . 41
PULLEY
DESCRIPTION
POWER STEERING PUMP PULLEY - 3.1L
DIESEL.............................41
REMOVAL.............................41
INSTALLATION.........................42
RESERVOIR
REMOVAL.............................42
INSTALLATION.........................42
WJPUMP 19 - 31

DIAGNOSIS AND TESTING - PUMP LEAKAGE
(1) Possible areas of pump leakage (Fig. 3).
STANDARD PROCEDURE
STANDARD PROCEDURE - INITIAL OPERATION
- 4.0L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - INITIAL OPERATION
- 4.7L
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
NOTE: Remove as much of the old fluid out of the
system as possible with a suction tool or by remov-
ing a hose, When a component has failed. Then
refill it with fresh fluid until it is clean. This may
have to be done more than once.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
then turn engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine, and use
the DRB III to activate the hydraulic fan on full fan
operation.
(8)
Turn the steering wheel slowly from lock to lock.
(9) Stop the engine, check the fluid level and refill
as required and repeat the process
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(10) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
Fig. 3 4.0L Power Steering Pump
WJPUMP 19 - 33
PUMP (Continued)

(11) While the vehicle is in park, use the DRB III
to activate the hydraulic fan to full fan operation and
briefly rev the engine up to 3000 rpm to fully engage
the hydraulic fan.
(12) Check the fluid level add if necessary.
REMOVAL
REMOVAL - 4.0L ENGINE
(1) Remove serpentine drive belt,(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove pressure and return hoses from pump
and drain the pump.
(3)
Loosen the pump bracket bolt at the engine block.
(4) Remove 3 pump mounting bolts (Fig. 4)
through pulley access holes.
(5) Tilt pump downward and remove from engine.
(6) Remove pulley from pump.
REMOVAL - 4.7L ENGINE
(1) Remove the serpentine drive belt,(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove the pressure and return hoses from
pump and drain pump.
(3) Remove 3 pump mounting bolts through pulley
access holes (Fig. 5).
(4) Remove the pump from the vehicle.
INSTALLATION
INSTALLATION - 4.0L ENGINE
(1) Install pulley on pump.
(2) Install pump on the engine mounting bracket.
(3) Install 3 pump mounting bolts and tighten to
27 N´m (20 ft. lbs.).
(4) Tighten pump bracket bolt to 57 N´m (42 ft.
lbs.).
(5) Install the pressure line on the pump and
tighten to 28 N´m (21 ft. lbs.).
(6) Install the return hoses on pump.
(7) Install the drive belt,(Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
(8) Add power steering fluid,(Refer to 19 - STEER-
ING/PUMP - STANDARD PROCEDURE).
INSTALLATION - 4.7L ENGINE
(1) Position the pump on the left cylinder head
and install bolts through pulley access holes. Tighten
bolts to 28 N´m (21 ft. lbs.).
(2) Install the pressure and return hoses to pump.
(3) Install serpentine drive belt,(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(4) Add power steering fluid,(Refer to 19 - STEER-
ING/PUMP - STANDARD PROCEDURE).
Fig. 4 PUMP MOUNTING ± 4.0L
1 - PUMP ASSEMBLY
2 - PUMP BRACKET
Fig. 5 Pump Mounting
1 - LEFT CYLINDER HEAD
2 - PUMP
19 - 34 PUMPWJ
PUMP (Continued)

INSTALLATION
NOTE: The pulley is marked front for installation.
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Replace pulley if bent, cracked, or loose.
(2) Install pulley on pump with Installer C-4063-B
or equivalent installer (Fig. 15). The front edge of the
pulley hub must be flush with the end of the shaft.
Ensure the tool and pulley are aligned with the
pump shaft.(3) Install pump assembly.
(4) With Serpentine Belt, run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.).Be
careful that pulley does not contact mounting
bolts.
RESERVOIR
REMOVAL
(1) Remove power steering pump.
(2) Clean exterior of pump.
(3) Clamp the pump body in a soft jaw vice.
NOTE: Use new retaining clips for installation.
(4) Pry up tab and slide the retaining clips off (Fig.
16).
(5) Remove fluid reservoir from pump body.
Remove and discard O-ring seal.
INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent.
(2) Install O-ring seal in housing.
(3) Install reservoir onto housing.
(4) Slide and tap innewreservoir retainer clips
until tab locks to housing.
(5) Install power steering pump.
(6) Add power steering fluid,(Refer to 19 - STEER-
ING/PUMP - STANDARD PROCEDURE).
Fig. 14 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4333
Fig. 15 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063±B
Fig. 16 Pump Reservoir Clips
1 - RESERVOIR
2 - RETAINING CLIPS
19 - 42 PUMPWJ
PULLEY (Continued)

STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT................71
STANDARD PROCEDURE - TRANSMISSION
FILL................................72
FRONT CLUTCH
DESCRIPTION.........................73
OPERATION...........................74
DISASSEMBLY.........................74
INSPECTION..........................74
ASSEMBLY............................74
FRONT SERVO
DESCRIPTION.........................77
OPERATION...........................77
DISASSEMBLY.........................77
CLEANING............................77
INSPECTION..........................77
ASSEMBLY............................77
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE..............................78
REMOVAL.............................78
INSTALLATION.........................79
ADJUSTMENTS - GEARSHIFT CABLE.......79
OIL PUMP
DESCRIPTION.........................80
OPERATION...........................80
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK......................81
DISASSEMBLY.........................81
CLEANING............................83
INSPECTION..........................83
ASSEMBLY............................83
OUTPUT SHAFT FRONT BEARING
REMOVAL.............................85
INSTALLATION.........................85
OUTPUT SHAFT REAR BEARING
REMOVAL.............................85
INSTALLATION.........................85
OVERDRIVE CLUTCH
DESCRIPTION.........................86
OPERATION...........................86
OVERDRIVE OFF SWITCH
DESCRIPTION.........................86
OPERATION...........................86
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS...............87
OVERDRIVE UNIT
REMOVAL.............................87
DISASSEMBLY.........................88
CLEANING............................95
INSPECTION..........................95
ASSEMBLY............................95
INSTALLATION........................104
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION........................105
OPERATION..........................105DISASSEMBLY........................106
CLEANING...........................106
INSPECTION.........................106
ASSEMBLY...........................106
PARK LOCK CABLE
REMOVAL............................108
INSTALLATION........................108
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH...................109
REMOVAL............................109
INSTALLATION........................109
PISTONS
DESCRIPTION........................110
OPERATION..........................110
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION........................112
OPERATION..........................112
DISASSEMBLY........................112
INSPECTION..........................113
ASSEMBLY...........................113
REAR CLUTCH
DESCRIPTION........................118
OPERATION..........................118
DISASSEMBLY........................119
CLEANING...........................119
INSPECTION.........................120
ASSEMBLY...........................120
REAR SERVO
DESCRIPTION........................122
OPERATION..........................122
DISASSEMBLY........................122
CLEANING...........................122
ASSEMBLY...........................123
SHIFT MECHANISM
DESCRIPTION........................123
OPERATION..........................123
REMOVAL............................123
INSTALLATION........................125
SOLENOID
DESCRIPTION........................125
OPERATION..........................126
SPEED SENSOR
DESCRIPTION........................126
OPERATION..........................126
THROTTLE VALVE CABLE
DESCRIPTION........................126
ADJUSTMENTS - TRANSMISSION THROTTLE
VALVE CABLE.......................126
TORQUE CONVERTER
DESCRIPTION........................128
OPERATION..........................132
REMOVAL............................133
INSTALLATION........................133
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION........................134
OPERATION..........................134
21 - 2 AUTOMATIC TRANSMISSION - 42REWJ