2003 JEEP GRAND CHEROKEE Steering pulley

DESCRIPTION N´m Ft. In.
Lbs. Lbs.
4.0L 4 Ð 32
4.7L 2 Ð 17
Fan Blade Assy. to Viscous
DriveÐ
Bolts 4.0L 23 Ð 200
Generator MountingÐBolts
4.0L57 42 Ð
Radiator Upper Isolator to
CrossmemberÐNuts 3 Ð 20
Radiator Upper Isolator to
RadiatorÐ
Nuts 4 Ð 36
Radiator BraceÐBolts 10 Ð 90
Thermostat HousingÐBolts
4.0L 22 16 Ð
4.7L 13 Ð 115
Upper Radiator Crossmember
to
BodyÐBolts 10 Ð 90
Water PumpÐBolts
4.0L 23 17 Ð
4.7L 54 40 Ð
Water Pump Pulley to Water
PumpÐ
Bolts 4.0L 28 Ð 250
High Pressure Inlet Hose to
Hydraulic Fan DriveÐ1/2 inch
Fitting49 36 Ð
High Pressure Outlet Hose to
Steering GearÐ3/8 inch
Fitting29 21.5 Ð
Fan Shroud to Radiator
Mounting Bolts6Ð50SPECIAL TOOLS
COOLING
Pliers 6094
Pressure Tester 7700±A
WJCOOLING 7 - 15
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
2. Incorrect belt. 2. Replace belt.
3. Tensile member damaged during
belt installation.3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
REMOVALÐ4.0L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts its stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 4).
INSTALLATIONÐ4.0L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 4).
Fig. 4 Belt RoutingÐ4.0L
1 - GENERATOR
2 - IDLER
3 - POWER STEERING
4 - A/C
5 - CRANKSHAFT
6 - WATER PUMP
7 - TENSIONER
8 - ACCESSORY DRIVE BELT
WJACCESSORY DRIVE 7 - 19
DRIVE BELTS - 4.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
2. Incorrect belt. 2. Replace belt.
3. Tensile member damaged during
belt installation.3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
REMOVAL - 4.7L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts its stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 7).
Fig. 7 Belt Routing - 4.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
7 - 22 ACCESSORY DRIVEWJ
DRIVE BELTS - 4.7L (Continued)

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)

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

PUMP
DESCRIPTION - 4.0L, 4.7L
Hydraulic pressure for the power steering system
is provided by a belt driven power steering pump
(Fig. 1) and (Fig. 2). The pump shaft has a
pressed-on drive pulley that is belt driven by the
crankshaft pulley.
OPERATION
OPERATION - 4.7L
The power steering pump is a constant flow rate
and displacement, vane-type pump. The pump has
internal parts that operate submerged in fluid. The
flow control orifice and the pressure relief valve,
which limits the pump pressure, are internal to the
pump. The reservoir is attached to the pump body
with spring clips. The power steering pump is used
to drive the hydraulic engine cooling fan, which sep-
arates the flow to the fan gerotors and the power
steering gear. The power steering pump is connected
to the engine cooling fan by pressure and return
hoses and the pump is connected to the steering gear
via a return hose from the steering cooler (Fig. 2).NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.OPERATION - 4.0L
The power steering pump is a constant flow rate
and displacement, vane-type pump. The pump inter-
nal parts operate submerged in fluid. The flow con-
trol orifice is part of the high pressure line fitting.
The pressure relief valve inside the flow control valve
limits the pump pressure. The reservoir is attached
to the pump body with spring clips. The power steer-
ing pump is connected to the steering gear by the
pressure and return hoses (Fig. 1).
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
Fig. 1 Pump With Integral Reservoir
1 - CAP
2 - FLUID RESERVOIR (TYPICAL)
3 - HIGH-PRESSURE FITTING
4 - DRIVE PULLEY
5 - PUMP BODY
6 - RESERVOIR CLIP
Fig. 2 4.7L POWER STEERING PUMP
1 - PRESSURE HOSE QUICK CONNECT NUT
2 - CAP
3 - FLUID RESERVOIR
4 - LOW-PRESSURE RETURN FROM THE COOLER
5 - LOW-PRESSURE RETURN FROM THE HYDRAULIC FAN
DRIVE
6 - PUMP BODY
7 - HIGH PRESSURE FITTING
19 - 32 PUMPWJ

(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)

SPECIAL TOOLS
POWER STEERING PUMP
FLUID COOLER
DESCRIPTION
4.7L models of this vehicle are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located at the front of the
vehicle. It is mounted to the radiator support just
forward of the air-conditioning condenser and just
rearward of the front fascia (Fig. 6). The cooler is
positioned so it is in the air flow through the front
fascia of the vehicle.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Drain the power steering fluid out of the reser-
voir.
(3) Remove the front fascia grille assembly,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - REMOVAL).
(4) Remove the grille opening reinforcement panel
(5) Place a drain pan under the cooler.
(6) Disconnect the lower hose at cooler (Fig. 6).
(7) Disconnect the upper hose at cooler (Fig. 6).
(8) Remove the three cooler mounting bolts (Fig.
6).
(9) Remove the cooler from the vehicle.
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
4.7L HYDRAULIC POWER STEERING TEST
ADAPTER KIT - 8630
Puller C-4333
Installer, Power Steering Pulley C-4063B
Fig. 6 POWER STEERING FLUID COOLER
1 - POWER STEERING COOLER
2 - POWER STEERING COOLER LINES CLIP
19 - 36 PUMPWJ
PUMP (Continued)