Jeep Cherokee

 Service Manual

Engine » 2.5L engine » Removal and installation
Engine

REMOVAL

(1) Disconnect the battery cables. Remove the battery.

(2) Mark the hinge locations on the hood panel for alignment reference during installation. Remove the engine compartment lamp. Remove the hood.

WARNING: THE COOLANT IN A RECENTLY OPERATED ENGINE IS HOT AND PRESSURIZED. USE CARE TO PREVENT SCALDING BY HOT COOLANT.

CAREFULLY RELEASE THE PRESSURE BEFORE REMOVING THE RADIATOR DRAIN COCK AND CAP.

(3) Loosen the radiator drain cock and radiator cap to drain the coolant. DO NOT waste usable coolant.

If the solution is clean, drain the coolant into a clean container for reuse.

(4) Remove the air cleaner assembly (Fig. 47).

(5) Remove the lower radiator hose.

Fig. 47 Air Cleaner and Resonator Removal and Installation

1 - AIR CLEANER ASSEMBLY
2 - NUT AND WASHER
3 - RESONATOR ASSEMBLY
4 - AIR INLET HOSE

(6) Remove the upper radiator hose and coolant recovery hose (Fig. 48).

(7) Remove the fan shroud (Fig. 48).

Fig. 48 Upper Radiator Hose, Coolant Recovery Hose & Fan Shroud

1 - UPPER RADIATOR HOSE
2 - FAN SHROUD
3 - COOLANT RECOVERY HOSE

(8) Remove the radiator/condenser (if equipped with air conditioning).

(9) Remove fan assembly and install a 5/16 x 1/2- inch SAE capscrew through fan pulley into water pump flange. This will maintain the pulley and water pump in alignment when crankshaft is rotated.

(10) Disconnect the heater hoses.

(11) Disconnect the throttle cable, speed control cable (if equipped) and transmission cable (if equipped).

(12) Disconnect the body ground at the firewall.

(13) Disconnect the wires from the starter motor solenoid.

(14) Disconnect all fuel injection harness connections.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE DISCONNECTING FUEL LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.

(15) Perform fuel pressure release procedure.

(refer to Group 14, Fuel System for the proper procedure).

(16) Remove latch clip and disconnect the quickconnect fuel line at the fuel rail (17) Recover refrigerant (if equipped with A/C).

(Refer to group 24, Heating and Air Conditioning for proper procedures.) (18) Disconnect suction/discharge hose from A/C compressor and cap off ports to prevent intrusion of foreign material or refrigerant oil loss.

(19) Remove the power brake vacuum check valve from the booster, if equipped.

(20) If equipped with power steering : (a) Disconnect the power steering hoses from the fittings at the steering gear.

(b) Drain the pump reservoir.

(c) Cap the fittings on the hoses and steering gear to prevent foreign material from entering the system.

(21) Identify, tag and disconnect all necessary wire connectors and vacuum hoses.

(22) Raise the vehicle.

(23) Remove the oil filter.

(24) Remove the starter motor.

(25) Disconnect the exhaust pipe from the exhaust manifold.

(26) Remove the flywheel housing access cover.

(27) Remove the upper flywheel and converter housing bolts and loosen the bottom bolts.

(28) Remove the engine support cushion-to-engine compartment bracket bolts.

(29) Remove the engine shock damper bracket from the sill.

(30) Lower the vehicle.

(31) Attach a lifting device to the engine.

(32) Raise the engine slightly off the front supports.

(33) Place a support stand under the converter or flywheel housing.

(34) Lift the engine out of the engine compartment and install on an engine stand.

(35) Install the oil filter to keep foreign material out of the engine.

INSTALLATION

(1) Remove the oil filter.

(2) Lift the engine off the stand and lower it into the engine compartment. For easier installation, it may be useful to remove the engine support cushions from the engine support brackets as an aide for alignment of the engine-to-transmission.

(3) Insert the transmission shaft into the clutch spline. (M/T models) (4) Align the flywheel housing with the engine.

(5) Install and tighten the flywheel housing lower bolts.

(6) Install the engine support cushions (if removed).

(7) Lower the engine and engine support cushions onto the engine compartment brackets.

(8) Remove the engine lifting device.

(9) Raise the vehicle.

(10) Install the converter-housing access cover.

(11) Install the exhaust pipe support.

(12) Install the starter motor and connect the cable. Tighten the bolts to 45 N·m (33 ft. lbs.) torque.

(13) Tighten the engine support cushion throughbolt nuts.

(14) Connect the exhaust pipe to the manifold.

(15) Install the oil filter.

(16) Lower the vehicle.

(17) Connect the coolant hoses and tighten the clamps.

(18) If equipped with power steering: (a) Remove the protective caps (b) Connect the hoses to the fittings at the steering gear. Tighten the nut to 52 N·m (38 ft. lbs.) torque.

(c) Fill the pump reservoir with fluid.

(19) Remove the pulley-to-water pump flange alignment capscrew and install the fan assembly.

(20) Install the fan shroud and radiator and condenser (if equipped with air conditioning).

(21) Connect the radiator hoses.

(22) Connect the oxygen sensor wire connector.

(23) Connect the throttle cable and install the rod.

Connect the transmission and speed control cables (if equipped) (24) Connect the fuel supply line to the injector rail. push until a "click" is heard. Re-install latch clip.

(25) Connect all the vacuum hoses and wire connectors.

(26) Connect suction/discharge hose to compressor.

(if equipped) (27) Fill the power steering reservoir.

(28) Connect the battery cables.

(29) Install the air cleaner (Fig. 47).

(30) Install the hood.

(31) Add engine oil and coolant.

(32) Start the engine and inspect for leaks.

(33) Stop the engine and check the fluid levels.

Add fluid, as required.

(34) Recharge air conditioning (Refer to group 24, Heating and Air Conditioning for proper procedures).

Engine mounts-front

Engine mount-rear

Engine

Intake manifold

Exhaust manifold

Cylinder head cover

Rocker arms and push rods

Valve spring and seal

Cylinder head

Cylinder head

Hydraulic tappets

Vibration damper

Timing case cover oil seal

Timing case cover

Timing chain and sprockets

Camshaft

Camshaft pin replacement

Camshaft bearings

Crankshaft main bearings

Oil pan

Oil pump

Piston and connecting rod

Rear main oil seal