5.7L Engine - Service Information: Removal & Installation Jeep Commander I

INSTALLATION - ENGINE

Scheme 216

Scheme 217

1. Install engine lift fixture Special tool # 8984 and 8984-UPD.
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine with transmission. 1 - ENGINE 2 - BOLTS 3 - TRANSMISSION
4. Mate engine (1) and transmission (3) and install two transmission to engine block mounting bolts (2) finger tight.
5. Lower engine assembly until the engine mounts (2) rests in frame perches (1). 1 - ENGINE 2 - BOLTS 3 - TRANSMISSION 1 - BOLTS
6. Install remaining transmission to engine block mounting bolts (2) and the oil pan to transmission bolts (1) and tighten.
7. Install and tighten engine mount to frame bolts (3) and nuts. 1 - Bolts
8. Install drive plate to torque converter bolts (1). 1 - STRUCTURAL COVER 2 - BOLTS
9. Install the structural dust cover (1).
10. Install the starter (1) and connect the starter wires. Refer to «INSTALLATION»(ref-288245-S19773464612008062000000) .
11. Install exhaust pipe to manifold.
12. Lower the vehicle. 1 - Bolts 2 - Engine Lift Fixture 3 - Adapter Bolt 4 - Adapter 5 - Adapter Nut
13. Remove engine lift fixture (2), special tool # 8984 and 8984-UPD. 1 - Heater Hose 2 - Clamp 3 - Tube 1 - Heater Hose 2 - Clamp 3 - Tube
14. Connect the fuel supply line. Refer to «STANDARD PROCEDURE»(ref-288225-S01749820952008062000000) .
15. Reinstall the power steering pump.
16. Connect the heater hoses (1).
17. Reconnect the ground wires to the rear of each cylinder head.
18. Install the intake manifold. See «INSTALLATION»(ref-288237-S28548216962008062000000) .
19. Install the generator (2), and wire connections. Refer to «INSTALLATION»(ref-288243-S17450075402008062000000) .
20. Install a/c compressor (3). Refer to «INSTALLATION»(ref-288218-S09515560042008062000000) . 1 - GENERATOR 2 - IDLER PULLEY 3 - WATER PUMP 4 - P/S PUMP 5 - A/C COMPRESSOR 6 - CRANKSHAFT 7 - BELT TENSIONER
21. Install the accessory drive belt. Refer to «INSTALLATION»(ref-288235-S21155267432008062000000) .
22. Install the radiator fan shroud. Refer to «INSTALLATION»(ref-288235-S08297703492008062000000) .
23. Connect the radiator lower hose.
24. Connect the transmission oil cooler lines to the radiator.
25. Connect the radiator upper hose.
26. Install the air cleaner resonator and duct work.
27. Add engine oil to crankcase. Refer to «SPECIFICATIONS»(ref-288217-S03476297422008062000000) .
28. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-288235-S07920148752008062000000) .
29. Install the engine cover (1).
30. Install the strut tower support (1).
31. Connect battery negative cable.
32. Start engine and inspect for leaks.
33. Road test vehicle.

INSTALLATION

1. Install filter element into housing.
2. Position housing cover into housing locating tabs.
3. Pry up 4 spring clips and lock cover to housing.
4. Install air duct to air cleaner cover and tighten hose clamp to 5 N.m (45 in. lbs.) torque.
5. If any other hose clamps were removed from air intake system, tighten them to 5 N.m (45 in. lbs.) torque.
6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 5 N.m (45 in. lbs.) torque.

REMOVAL

1. Disconnect the negative cable from the battery.
2. Remove the air cleaner. See «REMOVAL»(ref-288237-S25951639622008062000000) .
3. Remove intake manifold. See «REMOVAL»(ref-288237-S42058516752008062000000) .
4. Remove cylinder head cover. (See «REMOVAL»(ref-288237-S17377271092008062000000) ).
5. Remove rocker arm assembly and push rods. See «REMOVAL»(ref-288237-S29891810612008062000000) . Identify push rods to ensure installation in original location.
6. Remove the cylinder head. See «REMOVAL»(ref-288237-S42853754052008062000000) . 1 - TAPPET RETAINER 2 - HYDRAULIC ROLLER TAPPET
7. Remove bolt from tappet guide holder.
8. Remove tappet guide holder.
9. Pull tappet out of bore with a twisting motion. If all tappets are to be removed and reused, identify tappets to ensure installation in original location.
10. Check camshaft lobes for abnormal wear.

1. Lubricate tappets. 1 - TAPPET RETAINER 2 - HYDRAULIC ROLLER TAPPET
2. Install tappets in their original positions. CAUTION: 5.7L engines equipped with MDS uses both standard roller tappets and deactivating roller tappets, for use with the Multi Displacement System. The deactivating roller tappets must be used in cylinders 1,4,6,7. The deactivating tappets can be identified by the two holes in the side of the tappet body, for the latching pins.
3. Install tappet guide yoke. Install the tappet guide yoke bolt and tighten to 12 N.m (106 in. lbs.) torque.
4. Install cylinder head. See «INSTALLATION»(ref-288237-S19040867282008062000000) .
5. Install pushrods and rocker arm assembly. See «INSTALLATION»(ref-288237-S23627810702008062000000) .
6. Install cylinder head cover. (See «INSTALLATION»(ref-288237-S32582981352008062000000) ).
7. Install intake manifold. See «INSTALLATION»(ref-288237-S28548216962008062000000) .
8. Install the air cleaner.
9. Connect the negative cable to the battery. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
10. Road test vehicle and check for leaks.

1. Remove the 4 bolts (2) attaching the structural dust cover (1) to the transmission and the oil pan.
2. Remove the structural dust cover from the vehicle.

1. Position the structural dust cover (1) onto the oil pan and transmission.
2. Install the 4 bolts (2) and torque to 54 N.m (39 ft. lbs).

1. Remove engine cover (1).
2. Bleed fuel system. Refer to «STANDARD PROCEDURE»(ref-288225-S42279264532008062000000) .
3. Disconnect negative cable from battery.
4. Remove air inlet hose.
5. Remove ignition wires from on top of intake manifold.
6. Disconnect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Fuel Injectors ETC ( Electric Throttle Control )
7. Remove wire harness from intake manifold.
8. Disconnect brake booster hose, purge hose, and MUA hose ( Make Up Air Hose ).
9. Remove EGR tube from intake manifold.
10. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
11. Remove intake manifold as an assembly.

1. Position intake manifold.
2. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to 12 N.m (105 in. lbs.).
3. Install EGR tube.
4. Install wire harness on intake manifold.
5. Connect electrical connectors for the following components: Manifold Absolute Pressure (MAP) Sensor Fuel Injectors ETC ( Electronic Throttle Control )
6. Install ignition wires.
7. Connect Brake booster hose, purge hose, and MUA hose ( Make Up Air hose ).
8. Install air inlet hose.
9. Connect negative cable to battery.
10. Install engine cover (1).