Engine Removal Jeep Wrangler I

Removal (Cherokee, Comanche & Wrangler)

1. Remove battery and air cleaner. Remove hood (if necessary). Drain cooling system. Remove radiator hoses, coolant recovery hose and fan shroud. Disconnect transmission fluid cooler lines (if equipped).
2. Remove radiator and condenser. Discharge A/C system (if equipped). Remove fan assembly and install a 5/16" x 1/2" SAE cap screw through fan pulley into water pump flange to maintain pulley and water pump alignment when turning crankshaft.
3. Disconnect heater hoses, throttle linkages, cruise control cable (if equipped) and throttle valve rod. Disconnect wires from starter solenoid and all fuel injection harness connections.
4. Remove fuel tank cap to release fuel pressure. Disconnect fuel supply and return line at quick-disconnect fitting at chassis frame. Disconnect TDC sensor wire connector. Remove A/C service valves and cap compressor ports (if equipped).
5. Remove power brake vacuum check valve from booster (if equipped). Disconnect power steering hoses at steering gear (if equipped). Drain power steering pump reservoir. Cap power steering hoses and fittings.
6. Mark and disconnect all vacuum hoses and electrical connectors as required. Raise and support vehicle. Remove oxygen sensor. Disconnect exhaust pipe from exhaust manifold. Remove starter motor. Remove flywheel/converter housing access cover.
7. On A/T models, scribe/mark converter and drive plate location for installation. Remove converter-to-drive plate bolts. On all models, remove upper bellhousing bolts and loosen bottom bolts. Remove engine mount bolts.
8. Remove engine shock damper bracket. Lower vehicle. Attach lifting device and raise engine off front supports. Place support under bellhousing. Remove remaining bellhousing-to-engine bolts. Lift engine from engine compartment.

Installation (Cherokee & Comanche)

1. Attach lifting device to engine. Lower engine into engine compartment. NOTE: Remove engine mount cushions from engine mount brackets to ease engine-to-transmission alignment (if necessary).
2. If equipped with M/T, insert transmission shaft into clutch spline. Align flywheel housing with engine. Install and tighten flywheel housing lower bolts finger tight.
3. If equipped with A/T, align transmission torque converter housing with engine. Loosely install converter housing lower bolts and install next higher bolt and nut on each side. Tighten all four bolts finger tight.
4. Install engine mount cushions (if removed). Lower engine and engine mount cushions onto engine compartment brackets. Remove engine lifting device and raise vehicle.
5. If equipped with A/T, install converter-to-drive plate bolts. Ensure installation reference marks are aligned. Install converter-housing access cover. Install exhaust pipe support. Install remaining converter/flywheel housing bolts.
6. Install starter motor and connect cable. Torque bolts to specification. Torque engine mount cushion-to-bracket through bolts to specification. Install remaining converter/flywheel housing bolts and torque to specification.
7. Connect exhaust pipe to manifold. Lower vehicle. Connect coolant hoses and tighten clamps. Connect power steering hoses to steering gear and torque to specification. Remove pulley-to-water pump flange aligning cap screw and install fan assembly. Install and tighten drive belts. Install fan shroud and radiator/condenser (if equipped).
8. Connect radiator hoses. Connect A/T fluid cooler pipes (if equipped). Connect throttle valve rod and retainer. Connect throttle cable and install rod. Install throttle valve rod spring.
9. Connect cruise control cable (if equipped). Connect fuel supply and return lines to throttle body. Connect vacuum hoses and wire connectors. Connect CEC System wire harness connector at solenoid.
10. Connect service valves to A/C compressor ports (if equipped). Fill P/S reservoir. Connect battery cables. Install air cleaner. Install hood. Start engine. Inspect for leaks and correct fluid levels as necessary.

Installation (Wrangler)

1. Attach lifting device to engine. Lower engine into engine compartment. NOTE: To ease installation, it may be useful to remove engine mount cushions from engine mount brackets as an aide for alignment of engine-to-transmission.
2. Insert transmission shaft into clutch spline. Align flywheel housing with engine. Install and tighten flywheel housing lower bolts finger tight.
3. Remove support stand from beneath flywheel housing. Install engine mount cushions (if removed). Lower engine and engine mount cushions onto engine compartment brackets. Ensure bolt holes are aligned. Install and torque bolts to specification. Remove engine lifting device and raise vehicle.
4. Install exhaust pipe to manifold and torque nuts to specification. Install flywheel housing access cover. Install remaining flywheel housing bolts and torque to all bolts specification.
5. Install starter motor and connect cable. Torque bolts to specification. Lower vehicle. Connect coolant hoses and tighten clamps. Connect P/S hoses to steering gear and torque to specification. Remove pulley-to-water pump flange aligning cap screw and install fan assembly. Install and tighten drive belts. Install fan shroud and radiator.
6. Connect radiator hoses. Connect throttle valve rod and retainer. Connect throttle cable and install rod. Install throttle valve rod spring. Connect cruise control cable (if equipped).
7. Connect O2 sensor wire connector. Install vacuum hose and check valve for brake booster. Connect coolant temperature sensor wire connector. Connect idle speed actuator wire connector.
8. Connect fuel supply and return hoses at quick-connect fuel lines. Verify that quick-connect fitting assembly fits securely over fuel lines by giving fuel lines a firm tug.
9. Connect all fuel injection wire connections. Install engine ground strap. Connect ignition coil wire connector. Remove coolant temperature sending unit to permit air to escape from engine block. Fill cooling system with coolant. Install temperature sending unit when system is filled.
10. Fill P/S reservoir. Install battery and connect cables. Install air cleaner bonnet to throttle body and install air cleaner. Start engine. Inspect for leaks and correct fluid levels as necessary.

Removal (Cherokee, Comanche & Wagoneer)

1. Remove battery. Remove air cleaner. Mark hinge location and remove hood. Drain cooling system. Remove upper and lower radiator hoses, and coolant recovery hoses from radiator. Remove fan shroud. Disconnect A/T cooler pipe fittings at radiator (if equipped).
2. Discharge A/C system (if equipped). Remove radiator, condenser and fan assembly. Remove heater hoses. Disconnect throttle linkage, cruise control, and throttle valve cables (if equipped). Remove power brake booster vacuum hose (if equipped).
3. Mark and disconnect all wiring connectors and vacuum hoses to engine as required. Disconnect power steering pump with hoses and set aside (if equipped). WARNING: To prevent chance of personal injury, relieve residual pressure in PFI fuel system before opening system.
4. To release residual pressure in fuel system, remove fuel tank filler cap. Remove cap from pressure test port on fuel rail.
5. Place towels under fuel pressure test port. Using an appropriate tool, push test port valve in to relieve fuel pressure.
6. Disconnect A/C hoses at compressor (if equipped). Raise and support vehicle. Remove oxygen sensor. Disconnect speed sensor wire connector. Remove exhaust pipe support. Disconnect exhaust pipes at manifold.
7. Remove converter/flywheel housing cover. Disconnect flex plate from torque converter on A/T models. On all models, remove wiring at starter motor. Remove bellhousing-to-engine bolts. Lower vehicle and disconnect ground strap from left rear of cylinder head.
8. Remove air pump with hoses as an assembly. Attach lifting equipment to engine and support transmission. Remove engine mount through bolts. Lift engine and remove from vehicle.

Installation

1. Attach lifting device to engine. Lower engine into engine compartment. NOTE: To ease installation, it may be useful to remove engine mount cushions from engine mount brackets as an aide for alignment of engine-to-transmission.
2. If equipped with M/T, insert transmission shaft into clutch spline. Align flywheel housing with engine. Install and tighten flywheel housing lower bolts finger tight.
3. If equipped with A/T, align transmission torque converter housing with engine. Loosely install converter housing lower bolts and install next higher bolt and nut on each side. Tighten all four bolts finger tight.
4. Install engine mount cushions (if removed). Lower engine and engine mount cushions onto engine compartment brackets. Install bolts and finger tighten nuts. Remove engine lifting device. Raise and support vehicle. Install remaining flywheel/converter housing bolts and torque all bolts to specification.
5. If equipped with A/T, install converter-to-drive plate bolts. Ensure installation index marks are aligned.
6. Install flywheel/converter housing cover. Install exhaust pipe support and tighten screw. Tighten engine mount-to-bracket bolts. Connect engine speed sensor wire connections and tighten 2 screws. Connect exhaust pipe to manifold. Install starter motor and connect cable. Connect wires to starter motor solenoid. Lower vehicle. Connect vacuum hoses and wire connectors identified during removal.
7. If equipped with P/S, remove caps from fittings on hoses and steering gear. Connect P/S hoses to steering gear. Fill P/S pump reservoir.
8. Install power brake vacuum check valve in booster (if equipped). Connect fuel inlet and return lines at quick-connect connectors on fuel rail. Connect distributor electrical connector and oil pressure switch connector. Connect injection system wire harness connector on dash panel. Connect line pressure cable (if equipped with A/C). Connect cruise control cable (if equipped).
9. Connect throttle cable linkages. Connect heater hoses at thermostat housing and water pump. Install fan assembly. Install radiator (radiator/condenser if equipped with A/C). Connect radiator fan wire switch. Connect radiator hoses and A/C fluid cooler hoses (if equipped). Charge A/C system. Install fan shroud and electric cooling fan (if equipped with A/C). Install upper radiator support. Connect upper and lower radiator hoses and tighten clamps.
10. Fill cooling system with reusable coolant and/or new coolant. Install hood. Connect vacuum harness connector. Install air cleaner assembly. Connect battery negative cable. Start engine. Inspect for leaks and correct fluid levels as necessary.

Removal (Wrangler)

1. Remove battery. Drain cooling system. Remove air cleaner and engine compartment light from hood. Scribe hinge location and remove hood. Disconnect and plug front fuel line at pump and fuel return line at frame.
2. Disconnect heater hoses at heater. Mark and disconnect all wiring connectors, linkages and vacuum hoses as required. Remove vacuum switch assembly bracket from valve cover. Remove both radiator hoses and A/T oil lines (if equipped) at radiator. Remove radiator and shroud.
3. Remove fan and spacer. Use 5/16" x 1/2" SAE bolt to hold fan pulley to water pump flange. Discharge A/C system (if equipped).
4. Disconnect and plug hose or port openings at compressor. Disconnect hoses at power steering gear and drain reservoir. Remove power brake vacuum check valve and bracket bolt for A/T filler tube (if equipped).
5. Lift and support vehicle. Remove starter and disconnect engine ground strap. Remove engine mount-to-bracket nuts. Disconnect exhaust pipe at manifold. Remove converter housing cover (A/T).
6. On A/T models, index mark converter and flex plate for reassembly. Remove flex plate-to-converter bolts, rotating crankshaft to access each bolt. Remove oil pan bolts holding A/T oil lines.
7. On M/T models, remove flywheel housing cover. Remove inner support bolts for clutch release arm. Disconnect springs and remove clutch release arm. Remove outer bracket retainer for release lever rod. On all models, remove upper and loosen lower bellhousing bolts.
8. Lower vehicle. Support transmission. Remove idler pulley and mounting bracket (if equipped). Attach lifting equipment to engine. Raise engine off front mounts and remove lower bellhousing bolts. Lift engine from compartment while pulling forward.

1. Attach lifting device to engine. Lower engine into engine compartment. On vehicles with M/T, insert transmission shaft into clutch spline. Align flywheel housing with engine. Install and tighten lower flywheel housing bolts.
2. On vehicles with A/T, align transmission torque converter with engine. Loosely install converter housing lower bolts. Install next-higher bolt and nut on each side and tighten all four bolts.
3. Remove support from beneath flywheel/converter housing. Lower engine onto mount cushions. Ensure bolt holes are aligned and insert motor mount through bolts. Install through bolt nuts and torque all to specification.
4. Lift vehicle and support with stands. Install seal and attach exhaust pipe to manifold. Torque nuts to specification. If equipped with M/T, install flywheel housing access cover.
5. On vehicles with A/T, install converter-to-drive plate bolts (turn crankshaft to access each bolt hole). Ensure installation index marks are aligned. Install converter housing access cover. Install exhaust pipe support.
6. Install remaining flywheel/converter housing bolts. Install starter motor and connect cable. Lower vehicle and remove engine lifting device.
7. Install A/C compressor idler pulley and mounting bracket (if equipped and removed). Connect cooling system hoses and tighten clamps. Connect P/S hoses (if equipped). Install fan assembly and tighten belts. Install fan shroud and radiator. Connect radiator hoses and A/T cooler fluid pipes (if equipped).
8. Connect throttle valve rod and retainer. Connect throttle cable and install rod. Install throttle valve rod spring. Connect carburetor wire connectors. Connect O2 sensor wire connector.
9. Install vacuum hose and check valve on brake booster. Connect coolant temperature sender wire. Connect idle speed control solenoid wire. Connect carburetor bowl vent hose to canister tee. Connect fuel return hose to fuel filter.
10. Install transmission filler tube bracket screw (A/T only). Install vacuum switch assembly bracket. Remove plug and connect fuel pipe to fuel pump. Connect alternator wire connectors. Install engine ground strap. Connect oil pressure sender wire connector. Connect ignition system wire connectors.
11. On vehicles with A/C, connect compressor clutch wire. Connect service valve to port with replacement seals. Lubricate and tighten low pressure service valve nut to specification. Purge and charge A/C system.
12. Fill cooling system with coolant. Remove temperature sending unit to bleed air from block. Install temperature sending unit when system is full. Fill P/S reservoir with P/S fluid. Install battery.
13. Start engine, inspect for leaks and correct fluid levels as necessary. Install air cleaner and connect vacuum hose. Connect purge hose to canister. Install and adjust hood. Connect underhood lamp (if equipped).

Removal (Grand Wagoneer)

1. Remove battery. Drain cooling system. Scribe hinge location and remove hood. Remove air cleaner, radiator hoses and heater hoses. Disconnect A/T oil lines at radiator and at engine bracket. Remove radiator shroud.
2. Remove radiator and cooling fan assembly. Drain power steering reservoir and disconnect hoses (if equipped). Discharge A/C system and remove service valves from compressor (if equipped). Remove cruise control servo cable (if equipped) from carburetor linkage.
3. Separate wiring harness from engine and place aside. Remove fuel lines at tubing on frame. Disconnect power brake booster vacuum hose. Disconnect vacuum hose for heater damper doors at intake manifold. Detach transmission filler tube bracket at right cylinder head. DO NOT remove tube from transmission case.
4. Remove both engine front mount-to-frame retaining nuts. Support engine with lift equipment and remove upper bellhousing-to-engine bolts. Disconnect exhaust pipe at manifolds and remove starter.
5. Support transmission. Remove converter housing inspection cover. Index mark assembled position of converter and flex plate. Remove bolts holding flex plate to converter. Remove lower throttle valve and inner manual linkage support.
6. Disconnect throttle valve rod at lower end of bellcrank. Remove remaining bolts securing transmission. Pull forward while raising engine to remove from vehicle. Be careful to avoid damaging power brake unit (if equipped).

1. Attach lifting device to engine. Lower engine into engine compartment and align with drive plate housing. Install drive plate housing bolts and torque to specification.
2. Remove floor jack used to support transmission. Align assembly index marks. Install converter-to-drive plate bolts and torque to specification. Install inspection cover. Install starter motor. Lower engine onto supports and remove lifting device.
3. Install front support cushion retaining nuts and torque to specification. Connect exhaust pipe to manifolds and support bracket. Connect transmission filler tube bracket to right hand cylinder head.
4. Install cruise control vacuum servo bellows and mount bracket (if removed). Connect all wires, tubing, linkage and hoses to engine.
5. Connect receiver outlet to disconnect coupling. Connect condenser and evaporator lines to A/C compressor. Purge and recharge A/C. Connect P/S hoses and fill pump reservoir. Install radiator fan assembly. Install heater hoses. Install radiator and connect upper and lower hoses. Connect fluid cooler tubing. Fill cooling system and install air cleaner.
6. Start engine, inspect for leaks and correct fluid levels as necessary. Install and align hood assembly. Install transmission access cover, floor mat and transfer case shift lever boot.

2.5L

TORQUE SPECIFICATIONS (2.5L)

4.0L & 4.2L

TORQUE SPECIFICATIONS (4.0L & 4.2L)

5.9L

TORQUE SPECIFICATIONS (5.9L)