Tested

Procedure for removal of engine in 1993 Jeep Cherokee, 4.0L Inline 6 cylinder


1. Set E-Brake and ensure wheels are chocked.

2. Disconnect and remove battery

3. Drain engine oil, transmission fluid, radiator fluid.

4. Remove (R/) Oil filter

5. R/air filter and air filter housing

6. Remove and tag each end of all electrical lines you can find.

7. Disconnect lines attached to radiator. Take care with transmission cooling and A/C lines. Mainly look for hoses carrying water to the engine. You can leave the A/C lines and radiator in while removing engine.

8. R/the radiator support and fan shrouds. The fan on the right can be pulled out with ease. Care should be taken not to damage the radiator during this process.

9. Once the shrouds and fan is out of the way then remove the radiator.

10. R/ the fan from the engine. This will provide space when pulling the engine and reduce the risk of puncturing the radiator.

11. R/ the alternator and serpentine belt.

12. R/ the A/C pump from the four bolts. Leave it attached to the A/C lines. (Carefully secure it to the side)

13. R/ throttle body.

14. R/ EFI. (I have a question on this.) Is it possible to leave the EFI, intake and exhaust manifold on the engine while removing? I am just swapping engines and don’t really want to deal with all of this again?

15. R/ Intake manifold.

16. R/ exhaust manifold. (easier said than done)

17. R/ starter. Including the point where harness is attached to the engine.

18. R/ bolts from bell housing. Some type of lubricant sprayed on in advance might help loosen these bolts. (What is the tightening pattern for these upon reinstall?)

19. R/ flywheel from torque converter. You will need to place a wrench or large ratchet on the front of the engine to rotate the engine manually to get to all of the bolts. (What is the tightening pattern for these upon reinstall?)

20. Attach engine hoist (I had the head off so used the head bolts. Any guidance on where with all the junk still on?)

21. Pull long bolts on motor mounts.

22. Carefully remove engine while looking for anything that might still be attached to the motor or might be catching.

Well that’s what I got. Eventually I am going to try and make a list of required tools, sizes needed for each process and add some photos. Probably do those during the install.

Please read through this and give me any constructive comments you can.

cpnwrench

#7....."You can leave the A/C lines and radiator in while removing engine"

yet, in step #9... "Once the shrouds and fan is out of the way then remove the radiator."

Methinks you mean condenser ya?

Also btw, it is soooooo much easier if you....

remove grille
remove front bumper
remove radiator
condenser and lines from A/C unit (once compressor is unbolted from engine) can be pulled up and out of the way onto the fender area (of course with padding so no scratchee on paint).
then EVERYTHING on front of motor is so easy to get to.

just my two cents sir!

cpnwrench

Cherokee40

....Take lots of pictures from all angles for future/reinstall reference.....buy a box of ziplock baggies and a sharpie....bag bolts separately by section for reassembly....

Firestorm500

1. Remove hood.

2. Suspend Jeep upside down from a convenient beam or tree.

3. Shake the heck out of it and engine will fall out on the ground.

4. Installation is the reverse of disassembly.

Slick761

Yes!! Hope you used the winch!

Tested

Right on, thanks man. True I do mean the condenser. I'm guessing that's the one in front of the of the actual radiator.



All good points.

Tested

I am contemplating just leaving the EFI, intake and exhaust mounted to the engine. What thinks everyone?

cpnwrench

Tested........there should be no reason to remove from the engine the intake or exhaust or the EFI....unless you just want more clearance to pull it out..
you mentioned you are going to use the head bolts to attach hoist.

The 4.0L came with I thought attachment lifting bracket locations. I may be mistaken but one is at the very back of the exhaust /intake (firewall side) and the other is the back side of the alternator bracket area.

again, my two cents sir!

cpnwrench

Tested

Thanks man. I'll take a look.

milehigh94xj

Can you pull the 4.o with the transmission or remove one at a time?

jmu427

That is how I pulled mine: engine, trans and TC at once. I thought it would be easier than removing those separately. I did use a forklift which made it a lot easier too!

Gee oh Dee

Depends on space, tools, and lifting ability.

For me it would be easier to drop the trans and tcase then pull the motor.

milehigh94xj

That's what I'm going to try for. Doing it this weekend to this 93 sport I bought tday that has a large hole in the block

Tested

I am going to try and remove the engine and tranny as one part. Going to pull the radiator support off and then yank it out that way.

The thing I am wondering about is pulling the electrical that all goes to the engine. Mainly the EFI.

Does anyone know a quick way to do that?

Tested

I am overseas now but before I left we pulled the entire engine and tranny as one component. Much easier that way. Problem was getting those bolts that hold the tranny to the freaking engine. Pain in the ****.