4.7L V8 Engine: Removal & Installation Dodge Durango I

REMOVAL & INSTALLATION

Note. For installation reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies, as necessary, before removal.

Removal & Installation (Tab Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-98253-S03039446092001051800000). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. On 2-tab connectors, squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off fuel tube nipple. On single-tab connectors, use screwdriver to pry up pull tab. (Scheme 33) Raise pull tab until it separates from quick-connect fitting. Discard old pull tab. Disconnect quick-connect fitting from fuel line.
3. To install, coat fuel tube nipple with clean 30W engine oil. Insert quick-connect fitting into fuel tube until stop on fuel tube rests against back of quick-connect fitting.
4. On single-tab connectors, use NEW pull tab. Push tab down until it locks into quick-connect fitting. On 2-tab connectors, firmly pull on fuel tube and fitting to ensure retainer and quick-connect fitting are locked.

Scheme 33

Scheme 34

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-98253-S03039446092001051800000). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. Pull backward on disconnect fitting while depressing plastic ring into disconnect fitting. (Scheme 34) Separate fuel line from disconnect fitting. Plastic retainer ring must be pressed squarely into fitting body. If retainer is cocked during removal, it may be difficult to disconnect fitting. Use open-end wrench on shoulder of plastic retainer to ease disconnection.
3. To install, ensure plastic ring is in outward position (away from disconnect fitting). If plastic ring is in inward position (toward disconnect fitting), disconnect fitting must be replaced. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until shoulder on fuel line locks in place. CAUTION: DO NOT install a quick-connect fitting without retainer being either in fuel tube or already in quick-connect fitting. After installing fuel line in disconnect fitting, pull on fuel line and disconnect fitting to ensure fuel line is locked in place.
4. Pull on fuel line and disconnect fitting to ensure fuel line is locked in place. If fuel line is not locked in place, ensure plastic ring is not causing locking retainer to remain in released position. Reconnect negative battery cable. Start engine and check for leaks.

Removal & Installation (Dakota & Durango)

1. Disconnect negative battery cable. Remove battery and battery tray. Raise vehicle. Remove exhaust crossover pipe from exhaust manifolds. On 4WD vehicles, disconnect axle vent tube from left-side engine mount.
2. Remove through- bolt retaining nut and bolt from left and right side engine mounts. On 4WD vehicles, remove lock nut from left and right side engine mount brackets. Disconnect 2 grounding straps from lower left side, and one grounding strap from lower right side of engine. Disconnect crankshaft position sensor.
3. On 4WD vehicles with A/T, remove axle isolator bracket from engine, transmission and axle. Remove structural cover. (Scheme 35) Remove starter. Drain cooling system.
4. Remove torque converter bolts. Remove transmission-to-engine mounting bolts. Disconnect engine block heater cable, if equipped. Lower vehicle. Remove throttle body resonator assembly, and air inlet hose. Disconnect throttle and speed control cables.
5. Disconnect left and right side crankcase breather tubes. Remove breathers. Discharge A/C system using approved recovery/recycling equipment. Remove A/C compressor. Remove shroud, fan assembly and serpentine belt. Disconnect transmission cooler lines at radiator. Disconnect upper and lower radiator hoses. Remove radiator, A/C condenser and transmission oil cooler as an assembly.
6. Remove generator. Disconnect and remove heater hoses from timing chain cover and heater core. Disconnect necessary engine harness connectors, and vacuum lines and tag for reassembly. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-98253-S42188058272001051800000). Disconnect fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(ref-98253-S34287325402001051800000). (Scheme 33)and (Scheme 34). Remove power steering pump, and position aside. Install Lifting Studs (8400) into cylinder heads. Install Engine Lift Fixture (8347). (Scheme 36) Disconnect body grounding straps from left and right side cowls. Position a jack under transmission for support. Remove engine from vehicle.
7. To install, reverse removal procedure. Tighten structural cover bolts in sequence. (Scheme 35) Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000). Ensure marks on torque converter and flexplate are aligned. Refill cooling system. Evacuate and charge A/C system.

Removal & Installation (Grand Cherokee)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-98253-S42188058272001051800000). Remove front fascia/bumper, headlight mounting module, and radiator crossmember support.
2. Raise vehicle. Remove exhaust "Y" pipe. Remove structural cover bolts from engine and transmission, and remove cover. (Scheme 35) Drain cooling system. Remove starter and crankshaft position sensor. Remove transmission shift linkage as necessary. Remove torque converter cover bolts. Remove all transmission-to-engine bolts, except 2 lower bolts. Disconnect ground straps. Lower vehicle.
3. Remove throttle body resonator. Disconnect control cables from throttle body. Disconnect fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(ref-98253-S34287325402001051800000). (Scheme 33)and (Scheme 34). Disconnect necessary electrical connectors, vacuum lines and water hoses. Discharge A/C system using approved recovery/recycling equipment. Remove A/C compressor. Remove fan shroud, drive belt and radiator. Remove A/C condenser. Position generator and power steering pump aside.
4. Install Engine Lift Fixture (8347). (Scheme 36) Remove engine mount insulator-to-engine bolts. Support transmission with appropriate jack. Remove 2 lower transmission-to-engine bolts. Remove engine mount through-bolt nuts. While supporting transmission, raise engine and remove through-bolts, and engine mount insulators. Remove engine.
5. To install, reverse removal procedure. Tighten structural cover bolts in sequence. (Scheme 35) Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000). Ensure marks on torque converter and flexplate are aligned. Refill cooling system. Evacuate and charge A/C system.

Scheme 35

Scheme 36

Scheme 37

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-98253-S42188058272001051800000). Disconnect negative battery cable. Drain cooling system. Remove air cleaner housing, and throttle body resonator. Disconnect fuel lines at throttle body. Disconnect throttle and speed control cables. CAUTION: Fuel rail connector tube is integral with right and left fuel rails. DO NOT separate fuel rails from connector tube. DO NOT bend or kink connector tube.
2. Disconnect electrical connectors, water hoses, and vacuum hoses as necessary. Disconnect fuel injector electrical connectors. (Scheme 37) Remove generator bolts, and position generator aside. Remove A/C compressor mounting bolts, and position compressor aside. Remove ignition coils from spark plugs. Remove fuel rails and connector tube as assembly. Remove throttle body assembly.
3. Drain cooling system to appropriate level. Remove coolant temperature sensor. Remove cowl-to-hood seal and right side engine lifting stud. Remove intake manifold bolts in reverse order of tightening sequence. (Scheme 38) Remove intake manifold and gaskets.

Scheme 38

1. To install, reverse removal procedure. Tighten intake manifold bolts in sequence and to specification. (Scheme 38) See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000).

Removal (Right)

1. Remove battery. Remove Power Distribution Center (PDC) bolts and, position PDC for clearance. Remove battery tray and washer bottle. Remove drive belt. Remove A/C compressor bolts, and position compressor aside. Disconnect heater hoses from engine. Remove exhaust manifold heat shield. Remove upper exhaust manifold bolts.
2. Raise and support vehicle. Disconnect "Y" pipe. Remove starter bolts, and position starter aside. Remove lower exhaust manifold bolts, manifold, and gasket. .

Removal (Left)

1. Remove negative battery cable. Remove air cleaner housing and tube. Remove front bolts from exhaust manifold heat shield. Remove upper exhaust manifold bolts.
2. Raise vehicle. Disconnect "Y" pipe. Remove rear heat shield bolts, and remove heat shield. Remove lower exhaust manifold bolts, manifold and gasket.

Installation

To install, reverse removal procedure. Tighten bolts/nuts to specification, starting at center and working outward. See TORQUE SPECIFICATIONS .

Removal

1. Disconnect negative battery cable. Raise vehicle. Disconnect exhaust "Y" pipe at manifold. Drain coolant. Lower vehicle. Remove intake manifold. See «INTAKE MANIFOLD»(ref-98253-S00380449952001051800000). Remove valve cover. See «VALVE COVERS»(ref-98253-S29654544292001051800000). Remove fan shroud, and remove power steering pump.
2. Rotate crankshaft until timing mark is aligned with TDC indicator. Ensure "V8" marks on camshaft sprockets are at 12 o'clock position. See «TIMING CHAINS & SPROCKETS»(ref-98253-S01659898662001051800000). see scheme 12and see scheme 13. If necessary, rotate crankshaft one revolution. Remove crankshaft damper. Remove front cover. See «FRONT COVER»(ref-98253-S28638113952001051800000). CAUTION: DO NOT allow engine to rotate while timing chains are removed. Severe valve train damage can occur.
3. Using Secondary Chain Holder (8515), lock camshaft secondary timing chains to idler sprocket. see scheme 19 Mark one link on each side of "V8" mark on camshaft sprocket. Remove secondary chain tensioner. Remove cylinder head access plug, and remove secondary chain guide upper bolt. Remove secondary chain guide, camshaft sprocket bolt and sprocket. See «TIMING CHAINS & SPROCKETS»(ref-98253-S01659898662001051800000). Remove 14 cylinder head-to-block bolts. Remove cylinder head and gasket. CAUTION: DO NOT lay cylinder head on gasket surface. Due to gasket design, any distortion of cylinder head sealing surface could cause improper sealing.

Removal & Installation (Left Side)

1. Disconnect negative battery cable. Remove air cleaner housing and throttle body resonator. Disconnect injector and ignition coil electrical connectors, and position harness aside. Disconnect, and remove breather tube. Remove valve cover bolts, valve cover and gasket.
2. To install, reverse removal procedure. Inspect gasket, and replace if necessary. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000) .

Removal & Installation (Right Side)

1. Remove battery. Remove air cleaner housing, and throttle body resonator. Remove battery connector studs from Power Distribution Center (PDC). Unclip PDC, and position aside. Drain cooling system to appropriate level. Remove drive belt. Remove A/C compressor bolts, and position aside.
2. Remove battery tray. Disconnect heater hoses from front of engine. Loosen A/C accumulator bracket. Disconnect, and remove positive crankcase ventilation hose. Remove oil fill tube. Disconnect injector and ignition coil electrical connectors, and position harness aside. Remove valve cover bolts, valve cover and gasket.
3. To install, reverse removal procedure. Inspect gasket, and replace if necessary. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000) .

1. Disconnect negative battery cable. Remove drive belt. Remove A/C compressor bolts and set compressor aside. Drain cooling system. Remove upper radiator hose. Using Spanner Wrench (6950) with Adapter Pins (8346), loosen fan clutch from water pump. Remove fan clutch.
2. Disconnect electrical connector to fan mounted in shroud. Remove transmission cooler line from fan shroud, and remove shroud. Remove crankshaft damper bolt. Using Crankshaft Damper Removal Insert (8513) and Puller (1026), remove damper. Remove front seal using Front Crankshaft Seal Remover (8511).
3. To install, reverse removal procedure. Use Front Crankshaft Seal Installer (8348). Press damper onto crankshaft using Damper Installer (8512). Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000) .

Scheme 39

Scheme 40

1. Disconnect negative battery cable. Remove drive belt. Remove A/C compressor mounting bolts, and position compressor aside. Drain cooling system. Remove radiator hoses. Using Spanner Wrench (6958) with Adapter Pins (8346), remove fan and fan clutch from water pump.
2. Disconnect electrical connector to fan mounted in shroud. Remove transmission cooler line from fan shroud, and remove shroud. Disconnect heater hoses at front cover. Remove crankshaft damper bolt. Using Crankshaft Damper Removal Insert (8513) and Puller (1026), remove damper. Remove drive belt tensioner assembly. (Scheme 39) Remove front cover and gasket.
3. To install, reverse removal procedure. Tighten front cover bolts in sequence. (Scheme 40) Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000).

1. Using vise, lightly compress secondary chain piston until piston is flush with tensioner housing. Release ratchet pawl by pulling pawl back against spring force through tensioner side access hole. see scheme 18 While holding pawl back, push ratchet device to approximately.08" (2 mm) from tensioner housing.
2. Install Chain Tensioner Pin (8514) into hole at front of tensioner. Transfer piston spring force to lock pin by slowly opening vice. Position primary chain tensioner over oil pump and install bolts in 2 lower tensioner bracket holes. Tighten bolts to 20.7 ft. lbs. (28 N.m). Install right secondary chain tensioner arm, applying Mopar® lock and seal adhesive to bolt. Tighten bolt to 12 ft. lbs. (17 N.m). see scheme 16 NOTE: Chain guides are retained to cylinder heads by Silver bolts and to block by Black bolts.
3. Install left chain guide, and tighten bolts to 20.7 ft. lbs. (28 N.m). Install left secondary chain tensioner arm, applying Mopar® Lock & Seal Adhesive to bolt. Tighten bolt to 12 ft. lbs. (17 N.m). Install right chain guide, and tighten bolts to 20.7 ft. lbs. (28 N.m). see scheme 16 Install left and right secondary chain tensioners. Ensure tensioners are installed on correct sides. Install secondary chains on idler sprocket.
4. Position chains so 2 plated links are visible through lower slots in idler sprocket. see scheme 16 Using Secondary Chain Holder (8515), hold secondary chains in place for installation. see scheme 19 Align primary chain double-plated links with timing mark at 12 o'clock on idler sprocket. Align primary chain single-plated link with timing mark at 6 o'clock position on idler sprocket. see scheme 16 CAUTION: Ensure plate between left secondary chain tensioner and block is installed correctly. NOTE: Lubricate idler shaft and bushings with clean engine oil.
5. Install primary chain, secondary chains, crankshaft sprocket, and idler sprocket together as assembly. Guide secondary chains through block and cylinder head openings. Maintain tension on chains using elastic strap or equivalent. Align "L" dot on left sprocket, and "R" dot on right sprocket with plated links on secondary chains. see scheme 16
6. Remove Secondary Chain Holder (8515). Push both sprockets on camshafts. Install sprocket bolts, but do not tighten at this time. Verify all plated links are aligned with sprocket marks, and "V8" marks on sprockets are at 12 o'clock. see scheme 16 Lubricate and install idler sprocket bolt. Tighten bolt to 25 ft. lbs. (34 N.m). CAUTION: DO NOT manually extend tensioner ratchets after locking pins are removed from tensioners. see scheme 18 NOTE: Apply sealant to threads on right cylinder head plug before installing.
7. Remove locking pins from tensioners. Using Spanner (6958) with Adapter Pins (8346), tighten left and right sprocket bolts to 90 ft. lbs. (122 N.m). see scheme 20 Rotate engine 2 full revolutions, and verify timing mark alignments. see scheme 16
8. Check idler sprocket end play. If specifications are not within.004-.010" (.10-.25 mm), sprocket must be replaced. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove valve cover. See «VALVE COVERS»(ref-98253-S29654544292001051800000) . Rotate crankshaft to position pistons for rocker arm removal. See «ROCKER ARM R&I - PISTON POSITIONS»(ref-98253-S04934304592001051800000) table. Using Rocker Arm Removal Tool (8516) or equivalent, compress valve springs, and remove rocker arms. Remove lash adjusters. CAUTION: Before installing, ensure lash adjuster is full of oil and plunger does not have more than .059" (1.49) mm) travel.
2. To install, reverse removal procedure. Ensure lash adjusters are full of oil. Coat rocker arms with clean engine oil before installing. Install rocker arms in removal sequence. See «ROCKER ARM R&I - PISTON POSITIONS»(ref-98253-S04934304592001051800000) table. Ensure rocker arms are installed with concave pocket over lash adjuster.

ROCKER ARM R&I - PISTON POSITIONS

Note. Removal procedures apply to right and left camshafts unless noted otherwise.

1. Remove valve cover. See «VALVE COVERS»(ref-98253-S29654544292001051800000). Position No. 1 piston at TDC, and camshaft sprocket "V8" marks at 12 o'clock. Mark one link on secondary timing chain on both sides of sprocket "V8" mark for installation. see scheme 13 CAUTION: Chain tensioners must be secured before removing camshaft sprockets. Failure to secure tensioners will allow tensioners to extend, requiring front cover removal to reset tensioners. CAUTION: A damaged or magnetized target wheel, located on right camshaft sprocket, could cause a no start condition. DO NOT hold camshaft target wheel while loosening or tightening right camshaft sprocket. DO NOT place target wheel near any magnetic source. CAUTION: When removing camshaft sprocket, timing chains, or camshaft, Chain Tensioner Wedge (8350) MUST be used to prevent tensioner ratchet over extension, requiring front cover removal to reset ratchet. DO NOT force Chain Tensioner Wedge (8350) past narrowest point between chain strands.
2. Loosen, but DO NOT remove, camshaft sprocket retaining bolt. Leave bolt snug against sprocket. Place Chain Tensioner Wedge (8350) between chain strands, and tap tool to wedge timing chain against tensioner arm and guide. If removing right camshaft, remove camshaft position sensor from cylinder head. see scheme 17 On right and left camshafts, hold camshaft with adjustable pliers while removing sprocket bolt and sprocket. NOTE: Rocker arms could slide downward when removing camshaft(s). Mark rocker arms before removing camshaft.
3. Using adjustable pliers, slowly rotate right camshaft 45 degrees to a neutral position (no valve load). Rotate left camshaft 15 degrees to a neutral position. Starting at outside and working inward, loosen camshaft bearing retaining bolts 1/2 turn at a time. Repeat until load is off bearing caps. Remove camshaft bearing caps and camshaft.

Note. Installation procedures apply to left and right camshafts unless noted otherwise.

1. Lubricate journals with clean engine oil. Position left camshaft with camshaft sprocket dowel near one o'clock (neutral) position, and place in cylinder head. Position right camshaft with camshaft sprocket dowel near 10 o'clock (neutral) position, and place in cylinder head. Install camshaft bearing caps and hand tighten bolts. Working in 1/2 turn increments, tighten bearing cap bolts in sequence, and to specification. (Scheme 41) See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000).
2. Position camshaft sprocket onto timing chain. Align "V8" mark between 2 chain links (one on each side of sprocket) marked before removal. Using adjustable pliers, rotate camshaft until sprocket dowel aligns with slot in sprocket. Install sprocket on camshaft. Hand tighten sprocket bolt. Remove Chain Tensioner Wedge (8350).
3. Using Spanner Wrench (6958) and Adapter Pins (8346), tighten camshaft sprocket bolt to 90 ft. lbs. (122 N.m). Install valve cover. To complete installation, reverse removal procedure.

Scheme 41

1. Remove transmission. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICE. Remove flywheel/flexplate. Install Rear Crankshaft Seal Remover (8506) deep into seal, continuing to tighten into seal until tool can no longer be turned. Remove rear crankshaft seal.
2. To install, position Rear Crankshaft Seal Installer (8349-2) onto crankshaft rear face. Install crankshaft rear seal onto installer. Using Driver Handle (C-4171) and a hammer, tap seal into place. Tap on driver handle until seal installer seats against block crankshaft bore. To complete installation, install flywheel/flexplate, and transmission.

1. Disconnect negative battery cable. Drain cooling system. Remove upper radiator hose. Using Spanner Wrench (6958) with Adapter Pins (8346) and appropriate fan wrench, loosen fan drive. DO NOT attempt to remove fan clutch from water pump at this time. WARNING: Constant tension hose clamps are used. Wear safety glasses when servicing clamps. Use only tools designed for servicing clamps. When removing or installing hose clamps, use Clamp Remover/Installer (6094). Snap-On® Clamp Tool (HPC-20) may be used for larger clamps. CAUTION: When replacing constant tension clamp, use original equipment clamp matching number or letter stamped in tongue of clamp being replaced.
2. If replacing water pump, do not unbolt fan blade from fan clutch. Remove fan shroud-to-radiator nuts. DO NOT remove fan shroud by itself. Remove fan shroud and fan blade/fan clutch assembly as a unit
3. Locate drive belt tensioner, and rotate tensioner clockwise to release tension on drive belt. Note drive belt routing for installation reference. (Scheme 42)
4. Remove bolts and water pump pulley. Disconnect heater hoses and lower radiator hose. Remove coolant return tube from water pump. Remove water pump bolts and stud. Remove water pump and gasket.

To install, reverse removal procedure. Use NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fill system with coolant. Ensure accessory drive belt is installed in original direction to ensure proper rotation of water pump. (Scheme 42)

Scheme 42

Removal (Dakota & Durango)

1. Disconnect negative battery cable. Drain cooling system. Disconnect radiator hoses from radiator. Disconnect coolant reserve/overflow tank hose and washer bottle electrical connector and hose.
2. Remove upper fan shroud mounting screws. Lift upper fan shroud assembly up and out of engine compartment. Disconnect transmission oil cooler lines, if equipped.
3. Disconnect electric cooling fan motor connector. Remove 2 radiator upper mounting screws. Lift radiator upward and away from vehicle. Do not damage radiator cooling fins when removing radiator.

Installation Removal (Dakota & Durango)

1. Position isolator pins on bottom of radiator tanks into alignment holes in radiator lower support. Install and tighten radiator mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000) .
2. To complete installation, reverse removal procedure. Fill cooling system. Connect negative battery cable. Start and warm engine. Check for leaks.

Removal (2000 Grand Cherokee)

1. Disconnect negative battery cable. Drain cooling system. Using Spanner Wrench (6958) with Adapters (8346) and a 36 mm fan wrench, rotate fan drive/fan blade mounting nut counterclockwise, and remove thermal viscous fan drive. It is not necessary to remove drive belt.
2. Raise and support vehicle. Turn front wheels to access rivets, and remove plastic rivets attaching front fascia to wheel liner. (Scheme 44)
3. Remove bolts attaching fascia to fender. (Scheme 45) Remove plastic push pins attaching fascia to lower radiator crossmember splash shield. Disconnect fog lamp connectors, if equipped.
4. Remove screws attaching fascia to upper radiator crossmember. (Scheme 46) Slide fascia forward and remove from vehicle.
5. Remove 2 radiator mounting bolts. Disconnect both transmission cooler lines from radiator. Disconnect electric fan connector, then disconnect harness from shroud. Disconnect radiator hoses from radiator. CAUTION: If equipped with auxiliary transmission cooler, use caution when removing radiator. The oil cooler lines are routed through a rubber air seal on right side of radiator. Do not cut or tear this seal.
6. Disconnect overflow hose from radiator. Remove air inlet duct at grill. Gently lift up and remove radiator from vehicle. Do not scrape radiator fins against any other component.Also, do not disturb A/C condenser.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Removal (2001 Grand Cherokee)

1. Disconnect negative battery cable. Drain cooling system. Raise and support vehicle. Turn front wheels to access rivets, and remove plastic rivets attaching front fascia to wheel liner. (Scheme 44)
2. Remove bolts attaching fascia to fender. (Scheme 45) Remove plastic push pins attaching fascia to lower radiator crossmember splash shield. Disconnect fog lamp connectors, if equipped.
3. Remove screws attaching fascia to upper radiator crossmember. (Scheme 46) Slide fascia forward and remove from vehicle.
4. Remove 2 radiator mounting bolts. Disconnect both transmission cooler lines from radiator. Disconnect electrical connector for fan control solenoid. Disconnect power steering cooler line from cooler and filter.
5. Disconnect radiator hoses from radiator. Disconnect power steering cooler line from cooler and filter. Disconnect overflow hose from radiator. Remove air inlet duct at grill. NOTE: Radiator and cooling fan can be removed as an assembly. It is not necessary to remove cooling fan before removing or installing radiator.
6. Disconnect 2 high pressure fluid lines at hydraulic fan drive. Disconnect low pressure return at hydraulic fan drive. Gently lift up and remove radiator from vehicle. Do not scrape radiator fins against any other component.Also, do not disturb A/C condenser.

Installation (2000/01 Grand Cherokee)

1. Gently lower radiator into vehicle. Guide 2 radiator alignment dowels through holes in rubber air seals first and then through A/C support brackets.
2. Continue to guide alignment dowels into rubber grommets located in lower radiator crossmember. Holes in L-shaped brackets (located on bottom of A/C condenser) must be positioned between bottom of rubber air seals and top of rubber grommets.
3. Connect radiator hoses to radiator with tangs on hose clamps positioned straight down. To complete installation, reverse removal procedure. Fill cooling system. Connect negative battery cable. Start and warm engine. Check for leaks.

1. Disconnect negative battery cable. Drain cooling system. Raise and support vehicle. Remove splash shield. Disconnect lower radiator hose from thermostat housing.
2. Remove thermostat housing mounting bolts, thermostat housing and thermostat. (Scheme 47)
3. To install, clean timing chain cover and thermostat housing mating areas. Install thermostat with gasket into recessed groove in timing chain cover. (Scheme 47) CAUTION: Thermostat housing must be tightened evenly and thermostat must be centered into recessed groove in timing chain cover. If not, it may result in a cracked thermostat housing, damaged timing chain cover threads or coolant leaks.
4. Position thermostat housing on timing chain cover. Install thermostat housing mounting bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000).
5. Install lower radiator hose on thermostat housing. Install splash shield. Lower vehicle. Fill cooling system. Connect negative battery cable. Start and warm engine. Check for leaks.

Scheme 47

Removal (2X4)

Note. Oil pan gasket has integrated windage tray and steel carrier. Gasket assembly sealing area is molded rubber and can be reused if not damaged.

1. Disconnect negative battery cable. Drain the cooling system. Remove upper fan shroud. Remove throttle body resonator and air inlet hose. Remove intake manifold. Raise and support vehicle. Remove exhaust pipe at exhaust manifold. Remove structural cover. (Scheme 35) Drain engine oil and remove oil filter.
2. Position suitable jack under engine. Remove both left and right side engine mount through bolts. Raise engine to provide clearance to remove oil pan. Place blocks of wood between engine brackets and lower mounts to provide stability to engine. CAUTION: Oil pan gasket/windage tray assembly is attached to block in 3 locations. DO NOT pry on oil pan or oil pan gasket assembly when removing oil pan.
3. Remove oil pan bolts, and remove oil pan. Remove oil pump pickup tube. Remove oil pan gasket assembly (if necessary).

Removal (4X4)

Note. 4X4 vehicles equipped with 4.7L must have the front axle removed before oil pan can be removed.

1. Remove front axle from vehicle. Refer to «FRONT AXLE»(ref-125857-S29989013212001101500000) for 2000 models or «FRONT AXLE»(ref-125857-S29989013212001101500000) for 2001 models.
2. Remove structural cover. (Scheme 35) Drain engine oil and remove oil filter. CAUTION: Oil pan gasket/windage tray assembly is attached to block in 3 locations. DO NOT pry on oil pan or oil pan gasket assembly when removing oil pan.
3. Remove oil pan bolts, and remove oil pan. Remove oil pump pickup tube. Remove oil pan gasket assembly (if necessary).

Scheme 48

1. To install, reverse removal procedure. Inspect oil pan gasket assembly, and replace if necessary. To keep gasket assembly in alignment when installing, start 4 bolts at each corner before tightening oil pickup tube. Install oil pickup tube using NEW "O" ring.
2. Starting with "O" ring end of tube, tighten pickup tube bolts to 20 ft. lbs. (28 N.m). Install oil pan. Tighten bolts in sequence and to specification. (Scheme 48) See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000). To complete installation, reverse removal procedure.

Installation (4X4)

1. To install, reverse removal procedure. Inspect oil pan gasket assembly, and replace if necessary. To keep gasket assembly in alignment when installing, start 4 bolts at each corner before tightening oil pickup tube. Install oil pickup tube using NEW "O" ring.
2. Starting with "O" ring end of tube, tighten pickup tube bolts to 20 ft. lbs. (28 N.m). Install oil pan. Tighten bolts in sequence and to specification. (Scheme 48) See «TORQUE SPECIFICATIONS»(ref-98253-S08964724442001051800000).
3. Install front axle. Refer to «FRONT AXLE»(ref-125857-S29989013212001101500000) for 2000 models or «FRONT AXLE»(ref-125857-S29989013212001101500000) for 2001 models. To complete installation, reverse removal procedure.

Removal & Disassembly

1. Remove front cover. See «FRONT COVER»(ref-98253-S28638113952001051800000) under REMOVAL & INSTALLATION. Remove timing chains and tensioners. See «TIMING CHAINS & SPROCKETS»(ref-98253-S01659898662001051800000) under REMOVAL & INSTALLATION. Remove oil pump-to-crankshaft bolts, and primary chain tensioner bolts. Remove oil pump and tensioner. NOTE: Once oil pressure relief valve, cup plug, and pin are removed, pump assembly must be replaced.
2. To disassemble, remove oil pump cover screws and cover. Remove inner and outer rotors. If necessary to remove pressure relief valve, drive roll pin from pump housing and remove cup plug, spring and valve.