2003 JEEP GRAND CHEROKEE clamp & gasket

REMOVAL
REMOVALÐ4.0L ENGINE
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing (Refer to 7 -
COOLING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(2) Remove radiator upper hose and heater hose at
thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 24).
Discard old gasket.
(5) Clean the gasket mating surfaces.
REMOVALÐ4.7L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Remove splash shield.(5) Remove lower radiator hose clamp and lower
radiator hose at thermostat housing.
(6) Remove thermostat housing mounting bolts,
thermostat housing and thermostat (Fig. 25).
INSTALLATION
INSTALLATIONÐ4.0L ENGINE
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl-
inder head (Fig. 26).
(b) Position thermostat in groove with arrow and
air bleed hole on outer flange pointing up.
(2) Install replacement gasket and thermostat
housing.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess,
may result in a cracked housing.
(3) Tighten the housing bolts to 22 N´m (16 ft. lbs.)
torque.
(4) Install hoses to thermostat housing.
Fig. 24 Thermostat
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT
7 - 38 ENGINEWJ
ENGINE COOLANT THERMOSTAT (Continued)

WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drain sufficient coolant from the radiator to
decrease the level below the heater hose inlet. On
4.7L engines this requires complete draining.
(2) Remove the heater hose.
(3) Inspect the inlet for metal casting flash or
other restrictions.
NOTE: On 4.0L engines remove the pump from the
engine before removing restriction to prevent con-
tamination of the coolant with debris. . On 4.7L
engine remove the fitting from the timing chain
cover, If the restriction is in the timing chain cover,
remove the timing chain cover.
REMOVAL
The water pump on 4.7L engines is bolted directly
to the engine timing chain case/cover.
A gasket is used as a seal between the water pump
and timing chain case/cover.
The water pump can be removed without discharg-
ing the air conditioning system (if equipped).
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). Do not waste reusable
coolant. If solution is clean, drain coolant into a clean
container for reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(3) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove lower radiator hose clamp and remove
lower hose at water pump.
(5) Remove seven water pump mounting bolts and
one stud bolt.CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(6) Remove water pump and gasket. Discard gas-
ket.
CLEANING
Clean the gasket mating surface. Use caution not
to damage the gasket sealing surface.
INSPECTION
Inspect the water pump assembly for cracks in the
housing, Water leaks from shaft seal, Loose or rough
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.
INSTALLATION
(1) Clean gasket mating surfaces.
(2) Using a new gasket, position water pump and
install mounting bolts as shown. (Fig. 44). Tighten
water pump mounting bolts to 54 N´m (40 ft. lbs.)
torque.
(3) Spin water pump to be sure that pump impel-
ler does not rub against timing chain case/cover.
(4) Connect radiator lower hose to water pump.
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
Fig. 44 Water Pump Installation
1 - WATER PUMP
2 - TIMING CHAIN COVER
WJENGINE 7 - 49
WATER PUMP - 4.7L (Continued)

CLEANING
Clean the gasket mating surface. Use caution not
to damage the gasket sealing surface.
INSPECTION
Inspect the water pump assembly for cracks in the
housing, Water leaks from shaft seal, Loose or rough
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.
INSTALLATION
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.
(1) If pump is being replaced, install the heater
hose fitting to the pump. Use a sealant on the fitting
such as MopartThread Sealant With Teflon. Refer to
the directions on the package.
(2) Clean the gasket mating surfaces. If the origi-
nal pump is used, remove any deposits or other for-
eign material. Inspect the cylinder block and water
pump mating surfaces for erosion or damage from
cavitation.
(3) Install the gasket and water pump. The sili-
cone bead on the gasket should be facing the water
pump. Also, the gasket is installed dry. Tighten
mounting bolts to 30 N´m (22 ft. lbs.) torque. Rotate
the shaft by hand to be sure it turns freely.
(4) Connect the radiator and heater hoses to the
water pump.
(5) Position water pump pulley to water pump
hub. Tighten bolts 28 N´m (250 in. lbs.).
Install the idler pulley. Tighten the bolt 47 N´m (35
ft. lbs.).
Fig. 47 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 48 Clamp - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 49 Water Pump Remove/Install - Typical
1 - HEATER HOSE FITTING
2 - PUMP GASKET
3 - WATER PUMP
4 - LONG BOLT
5 - BOLTS (4) SHORT
7 - 52 ENGINEWJ
WATER PUMP - 4.0L (Continued)

INSPECTION
Visually inspect the pressure valve gasket on the
cap. Replace cap if the gasket is swollen, torn or
worn. Inspect the area around radiator filler neck for
white deposits that indicate a leaking cap.
WATER PUMP INLET TUBE
REMOVAL
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 53). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(1) Partially drain cooling system .
(2) Do not waste reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.(3) Loosen both bypass hose clamps (Fig. 52) and
position to center of hose. Remove hose from vehicle.
INSTALLATION
(1) Position bypass hose clamps (Fig. 52) to center
of hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps (Fig. 52).
(4) Refill cooling system .
(5) Start and warm the engine. Check for leaks.
Fig. 51 Pressure Testing Radiator Pressure
CapÐTypical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
Fig. 52 Hose Clamp ToolÐTypical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 53 Clamp Number/Letter Location
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
7 - 54 ENGINEWJ
RADIATOR PRESSURE CAP (Continued)

(6) While pulling assembly from engine, note direc-
tion and position of pulse ring (Fig. 6). After removal,
look down into top of oil pump and note direction and
position of slot at top of oil pump gear.
(7) Remove and discard old oil pump drive-to-en-
gine block gasket.
REMOVAL - 4.7L
The Camshaft Position Sensor (CMP) on the 4.7L
V±8 engine is bolted to the front/top of the right cyl-
inder head (Fig. 10).
It is easier to remove/install sensor from under
vehicle.
(1) Raise and support vehicle.
(2) Disconnect electrical connector at CMP sensor
(Fig. 10).
(3) Remove sensor mounting bolt (Fig. 10).
(4) Carefully pry sensor from cylinder head in a
rocking action with two small screwdrivers.Some
4.7L engines are equipped with a sensor spacer
shim. If equipped, this shim will be located at
sensor bolt hole between cylinder head and
sensor mounting tang (TSB W08±18±00). Save
this shim for sensor installation.
(5) Check condition of sensor o-ring.
Fig. 7 CMP Location - 4.0L Engine
1 - OIL FILTER
2 - CAMSHAFT POSITION SENSOR
3 - CLAMP BOLT
4 - HOLD-DOWN CLAMP
5 - MOUNTING BOLTS (2)
6 - ELEC. CONNECTOR
Fig. 8 CMP Pulse Ring Alignment - 4.0L Engine
1 - PULSE RING (SHUTTER)
2 - TOOTHPICK
3 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
Fig. 9 Align Timing Marks - 4.0L Engine
1 - CRANKSHAFT VIBRATION DAMPER TIMING MARK
WJIGNITION CONTROL 8I - 7
CAMSHAFT POSITION SENSOR (Continued)

(32) Install valve body as follows:
(a) Align and carefully insert park rod into pawl.
Rod will make click noise as it enters pawl. Move
rod slightly to check engagement.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case. Also be sure valve body wiring
is not pinched or kinked.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a diag-
onal pattern to 12 N´m (105 in. lbs.) torque. Do not
overtighten valve body bolts. This could result in
distortion and cross leakage after installation.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) Install new filter on valve body. Tighten filter
screws to 4 N´m (35 in. lbs.).
(34) Adjust front and rear bands.
(35) Install seal on park/neutral position switch.
Then install and tighten switch to 34 N´m (25 ft.
lbs.).
(36) Install magnet in oil pan. Magnet goes on
small protrusion at corner of pan.
(37) Position new oil pan gasket on case and
install oil pan. Tighten pan bolts to 17 N´m (13 ft.
lbs.).
(38) Install new valve body manual shaft seal in
case (Fig. 60). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(39) Install throttle valve and shift selector levers
on valve body manual lever shaft.INSTALLATION
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal during installa-
tion.
(2) Lubricate oil pump seal lip with transmission
fluid.
(3) Align converter and oil pump.
(4) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(5) Check converter seating with steel scale and
straightedge (Fig. 61). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(6) Temporarily secure converter with C-clamp.
(7) Position transmission on jack and secure it
with chains.
(8) 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 trans-
mission in alignment.
(9) Apply a light coating of MopartHigh Temp
grease to the torque converter hub pocket in the rear
of the crankshaft
(10) Raise transmission and align converter with
drive plate and converter housing with engine block.
Fig. 60 Installing Manual Lever Shaft Seal
1 - 15/1688SOCKET
2 - SEAL
Fig. 61 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 41
AUTOMATIC TRANSMISSION - 42RE (Continued)

(8) Install new seals on over drive piston.
(9) Stand transmission case upright on bellhous-
ing.
(10) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(11) Position Seal Guide 8114-2 on inner edge of
overdrive piston retainer.
(12) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114-2 and
inside Guide Ring 8114-1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
NOTE: Install the remaining transmission compo-
nents and the overdrive unit.
PARK LOCK CABLE
REMOVAL
(1) Place the shifter in the PARK position.
(2) Lower the steering column cover.
(3) With the ignition switch in the ªRUNº position
depress the park lock cable locking tab, located on
top of the cable connector at the steering column and
pull the park lock cable straight out.
(4) Remove the park lock cable from steering col-
umn (Fig. 197).
(5) Remove the floor console and related trim.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(6) Disconnect the park lock cable from the shift
BTSI lever and remove the cable from the shifter
assembly bracket.
(7) Release the park lock cable from any remaining
clips.
(8) Remove park lock cable from the vehicle.
INSTALLATION
NOTE: The gearshift cable must be secured into
position and properly adjusted before the installa-
tion of the Park Lock Cable.
(1) Verify that the shifter is in the PARK position.
(2) Push the park lock cable straight into the
square mounting hole in the steering column until
cable snaps in place.
(3) Route park lock cable to the shifter mecha-
nism.
(4) Install the park lock cable end fitting into
shifter BTSI lever.
(5) Pull rearward on the cable housing to snap
park lock cable adjuster ears into floor shifter
bracket.
(6) Place the ignition key cylinder in the ACCES-
SORY position.
(7) Push the cable adjuster lock clamp downward
to lock it.
(8) Test the park lock cable operation.
(9) Install the floor console and related trim.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
INSTALLATION)
Fig. 196 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
21 - 108 AUTOMATIC TRANSMISSION - 42REWJ
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

HEATER CORE
DESCRIPTION
The heater core is located in the HVAC housing,
under the instrument panel. It is a heat exchanger
made of rows of tubes and fins.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The temperature
control door allows control of the heater output air
temperature by controlling how much of the air flow-
ing through the HVAC housing is directed through
the heater core. The blower motor speed controls the
volume of air flowing through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced. Refer to Cooling for
more information on the engine cooling system, the
engine coolant and the heater hoses.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Remove the foam gasket surrounding the core
tubes.
NOTE: Notice the orientation of the irregularly
shaped gasket on the tubes. The gasket must be
placed correctly to ensure proper sealing against
the body during reinstallation.(3)
Remove the screws and retainers that secure the
heater core and tubes to the HVAC housing (Fig. 12).
(4) Remove the mode door actuator if necessary,
for clearance to remove the core.
(5) Lift the heater core straight up and out of the
HVAC housing (Fig. 13).
(6) When replacing individual tubes, loosen and
remove the round tube-to-core clamp, and pull tube
from core.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
Fig. 12 HEATER CORE, TUBES, AND RETAINERS
1 - TUBE-TO-CORE CLAMPS
2 - GROUND STRAP
3 - HVAC HOUSING
4 - TUBE RETAINERS AND SCREWS
5 - HEATER CORE
WJPLUMBING 24 - 71