(8) Install the drain plug. Tighten drain plug to 34
N·m (25 ft. lbs.) torque.
(9) Install exhaust pipe.
(10) Connect the oxygen sensor.
(11) Install the oil filter.
(12) If equipped with an oil level sensor, connect
the sensor.
(13) Install the starter (refer to Group 8B, Battery/
Starter/Generator Service).
(14) Move the cooler lines back into position.
(15) Lower vehicle.
(16) Connect the negative cable to the battery.
(17) Fill the oil pan with engine oil to the specified
level.
WARNING:
USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(18) Start the engine and inspect for leaks.
PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to cen-
ter the connecting rod in the cylinder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
INSTALLATION
(1) Be sure that compression ring gaps are stag-
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 39).
(3) Immerse the piston head and rings in clean
engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
Fig. 38 Position of Dowels in Cylinder Block
DOWEL
DOWEL
DOWEL
DOWEL
Fig. 39 Proper Ring Installation
OIL RING SPACER GAP
SECOND
COM-
PRESSION
RING
GAP
OIL
RING
RAIL GAP (TOP)
OIL RING RAIL GAP (BOTTOM)
TOP
COMPRES-
SION RING GAP
9 - 72
5.2L ENGINE
ZG
REMOVAL AND INSTALLATION (Continued)
Summary of Contents for 1997 Grand Cherokee
Page 6: ...FASTENER IDENTIFICATION 4 INTRODUCTION ZG GENERAL INFORMATION Continued ...
Page 9: ...METRIC CONVERSION ZG INTRODUCTION 7 GENERAL INFORMATION Continued ...
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Page 282: ...COOLING SYSTEM DIAGNOSIS DIESEL ENGINE 7 8 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 283: ...ZG COOLING SYSTEM 7 9 DIAGNOSIS AND TESTING Continued ...
Page 284: ...7 10 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 285: ...ZG COOLING SYSTEM 7 11 DIAGNOSIS AND TESTING Continued ...
Page 286: ...7 12 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
Page 290: ...SERPENTINE DRIVE BELT DIAGNOSIS 7 16 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...
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Page 423: ...VIC Initial Set Up ZG INSTRUMENT PANEL SYSTEMS 8E 21 SERVICE PROCEDURES Continued ...
Page 424: ...VIC Reset 8E 22 INSTRUMENT PANEL SYSTEMS ZG SERVICE PROCEDURES Continued ...
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Page 1655: ...Fig 3 Oil Lubrication System ZG 5 2L ENGINE 9 57 DESCRIPTION AND OPERATION Continued ...
Page 1684: ...TORQUE 9 86 5 2L ENGINE ZG SPECIFICATIONS Continued ...
Page 1689: ...Fig 3 Oil Lubrication System ZG 5 9L ENGINE 9 91 DESCRIPTION AND OPERATION Continued ...
Page 1723: ...DIAGNOSIS AND TESTING SERVICE DIAGNOSIS DIESEL PERFORMANCE ZG ENGINE 9 3 ...
Page 1724: ...9 4 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1725: ...ZG ENGINE 9 5 DIAGNOSIS AND TESTING Continued ...
Page 1726: ...9 6 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1727: ...ZG ENGINE 9 7 DIAGNOSIS AND TESTING Continued ...
Page 1728: ...9 8 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1729: ...SERVICE DIAGNOSIS DIESEL MECHANICAL ZG ENGINE 9 9 DIAGNOSIS AND TESTING Continued ...
Page 1730: ...9 10 ENGINE ZG DIAGNOSIS AND TESTING Continued ...
Page 1731: ...ZG ENGINE 9 11 DIAGNOSIS AND TESTING Continued ...
Page 1762: ...SPECIFICATIONS ENGINE SPECIFICATIONS 9 42 ENGINE ZG ...
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Page 2122: ...DIAGNOSIS AND TESTING NV231 DIAGNOSIS 21 8 TRANSMISSION AND TRANSFER CASE ZG ...