2002 JEEP LIBERTY pcm

FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
OPERATION
The fuel pump module has 4 different circuits
(wires). Two of these circuits are used for the fuel
gauge sending unit for fuel gauge operation, and for
certain OBD II emission requirements. The other 2
wires are used for electric fuel pump operation.
For Fuel Gauge Operation:A constant current
source of approximately 32 milliamps is supplied to
the resistor track on the fuel gauge sending unit.
This is fed directly from the Powertrain Control Mod-
ule (PCM).NOTE: For diagnostic purposes, this
12V power source can only be verified with the
circuit opened (fuel pump module electrical
connector unplugged). With the connectors
plugged, output voltages will vary from about
0.6 volts at FULL, to about 8.6 volts at EMPTY
(about 8.6 volts at EMPTY for Jeep models, and
about 7.0 volts at EMPTY for Dodge Truck mod-
els).The resistor track is used to vary the voltage
(resistance) depending on fuel tank float level. As
fuel level increases, the float and arm move up,
which decreases voltage. As fuel level decreases, the
float and arm move down, which increases voltage.
The varied voltage signal is returned back to the
PCM through the sensor return circuit.
Both of the electrical circuits between the fuel
gauge sending unit and the PCM are hard-wired (not
multi-plexed). After the voltage signal is sent from
the resistor track, and back to the PCM, the PCM
will interpret the resistance (voltage) data and send
a message across the multi-plex bus circuits to the
instrument panel cluster. Here it is translated into
the appropriate fuel gauge level reading. Refer to
Instrument Panel for additional information.
For OBD II Emission Monitor Requirements:
The PCM will monitor the voltage output sent from
the resistor track on the sending unit to indicate fuel
level. The purpose of this feature is to prevent the
OBD II system from recording/setting false misfire
and fuel system monitor diagnostic trouble codes.
The feature is activated if the fuel level in the tank
is less than approximately 15 percent of its rated
capacity. If equipped with a Leak Detection Pump
(EVAP system monitor), this feature will also be acti-
vated if the fuel level in the tank is more than
approximately 85 percent of its rated capacity.
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT
The fuel level sending unit contains a variable
resistor (track). As the float moves up or down, elec-
trical resistance will change. Refer to Instrument
Panel and Gauges for Fuel Gauge testing. To test the
gauge sending unit only, it must be removed from
vehicle. The unit is a separate part of the lower fuel
pump module section. Refer to Fuel Pump Module
Removal/Installation for procedures (remove only the
upper section of the fuel pump module). Measure the
resistance across the sending unit terminals. With
float in up position, resistance should be 20 ohms (+/-
5%). With float in down position, resistance should be
270 ohms (+/- 5%).
REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the lower sec-
tion of the fuel pump module. The lower section of
the fuel pump module is located within the fuel tank.
(1) Remove lower section of fuel pump module
from fuel tank. Refer to Fuel Pump Module Removal/
Installation.
(2) To remove sending unit from pump module, lift
on plastic locking tab (Fig. 8) while sliding sending
unit upwards.
(3) Disconnect 4±wire electrical connector (Fig. 9)
from bottom of upper section of fuel pump module.
Separate necessary sending unit wiring.
Fig. 8 FUEL LEVEL SENDING UNIT
1 - LIFT TAB HERE FOR REMOVAL
2 - FUEL LEVEL SENDING UNIT
3 - LOWER SECTION OF PUMP MODULE
KJFUEL DELIVERY 14 - 9

OPERATION
The fuel pressure regulator is a mechanical device
that is not controlled by engine vacuum or the Pow-
ertrain Control Module (PCM).
The regulator is calibrated to maintain fuel system
operating pressure of approximately 339 kPa +/- 34
kPa (49.2 psi +/- 5 psi) at the fuel injectors. It con-
tains a diaphragm, calibrated springs and a fuel
return valve.
The main fuel filteris not combinedwithin the
fuel pressure regulator as in other Jeeptmodels.
Three different fuel filters are used: 1. a serviceable,
separate, externally mounted, main fuel filter; 2. a
non-serviceable primary filter located on the bottom
of the electric fuel pump; 3. a non-serviceable second-
ary filter attached to the side of the fuel pump mod-
ule.
Fuel Flow:Fuel migrates into the fuel pump mod-
ule reservoir through a one-way check valve located
on the bottom of the module. This check valve pre-
vents the reservoir from running empty such as
when going up or down hills with a low amount of
fuel in the tank. A primary fuel filter (sock) is located
at the bottom of the electric fuel pump. Fuel is drawn
in through this filter, and up to the electric fuel
pump. High pressure fuel (unregulated) is supplied
from the electric fuel pump through a high-pressure
line to one of 3 fittings on the main fuel filter. If fuel
pressure at the pressure regulator exceeds approxi-
mately 49 psi, an internal diaphragm within the reg-
ulator closes, and excess fuel is routed through a
second fitting on the main fuel filter, and back into
the fuel tank (the fuel pressure regulator is installed
into the return side of the system). Pressure regu-
lated fuel is then delivered from the third fitting on
the fuel filter, up to and through the fuel rail, and on
to the fuel injectors.
A secondary fuel filter is attached to the side of the
fuel pump module. High-pressure from the electric
fuel pump causes a siphoning action across a passage
connected to this filter, and fuel is drawn into the
fuel pump module reservoir. This is used to help keep
the module reservoir full of fuel.
The fuel pressure regulator also acts as a check
valve to maintain some fuel pressure when the
engine is not operating. This will help to start the
engine. A second check valve is located at the outlet
of the fuel pump module housing.Refer to Fuel
Pump - Description and Operation for more
information. Also refer to the Fuel Pressure
Leak Down Test, and the Fuel Pump Pressure
Tests.
A separate fuel return line from the engine is not
used with this system.
REMOVAL
The fuel pressure regulator is located in the fuel
tank. It is attached to the bottom of the upper sec-
tion of the fuel pump module with a quick-connect
fitting (Fig. 19). The fuel pump module is supplied in
2 sections (upper and lower). To replace the pressure
regulator, the bottom section of the fuel pump mod-
ule must be replaced.
(1) Remove upper and lower sections of fuel pump
module from fuel tank. Refer to Fuel Pump Module
Removal/Installation.
(2) Replace lower section of fuel pump module
(includes fuel pressure regulator).
INSTALLATION
The fuel pressure regulator is located in the fuel
tank. It is attached to the bottom of the upper sec-
tion of the fuel pump module with a quick-connect
fitting. The fuel pump module is supplied in 2 sec-
tions (upper and lower). To replace the pressure reg-
ulator, the bottom section of the fuel pump module
must be replaced.
(1) Replace lower section of fuel pump module
(includes fuel pressure regulator).
(2) Install upper and lower sections of fuel pump
module to fuel tank. Refer to Fuel Pump Module
Installation.
Fig. 19 FUEL PRESSURE REGULATOR/SENDING
UNIT ELECTRICAL CONNECTOR
1 - UPPER SECTION OF PUMP MODULE
2 - QUICK-CONNECT FITTINGS
3 - FUEL PRESSURE REGULATOR
4 - 4-WIRE ELECTRICAL CONNECTOR
5 - FUEL TANK CHECK (CONTROL) VALVE
14 - 14 FUEL DELIVERYKJ
FUEL PRESSURE REGULATOR (Continued)

FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
DESCRIPTION.........................29
ACCELERATOR PEDAL
REMOVAL.............................29
INSTALLATION.........................30
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................30
OPERATION...........................31
REMOVAL.............................31
INSTALLATION.........................32
FUEL INJECTOR
DESCRIPTION.........................33
OPERATION
OPERATION - FUEL INJECTOR..........33
OPERATION - PCM OUTPUT............33
DIAGNOSIS AND TESTING - FUEL INJECTOR . 33
REMOVAL.............................34
INSTALLATION.........................34
FUEL PUMP RELAY
DESCRIPTION.........................34
OPERATION...........................34
DIAGNOSIS AND TESTING - FUEL PUMP
RELAY..............................34
REMOVAL.............................34
INSTALLATION.........................34
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................36INSTALLATION.........................36
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL.............................37
INSTALLATION.........................38
MAP SENSOR
DESCRIPTION.........................38
OPERATION...........................38
REMOVAL.............................39
INSTALLATION.........................40
OXYGEN SENSOR
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................41
INSTALLATION.........................43
THROTTLE BODY
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................43
INSTALLATION.........................44
THROTTLE CONTROL CABLE
REMOVAL.............................45
INSTALLATION.........................46
THROTTLE POSITION SENSOR
DESCRIPTION.........................47
OPERATION...........................47
REMOVAL.............................47
INSTALLATION.........................48
FUEL INJECTION
DESCRIPTION
The Powertrain Control Module (PCM) operates
the fuel injection system. Refer to Powertrain Control
Module in Electronic Control Modules for informa-
tion.
ACCELERATOR PEDAL
REMOVAL
The accelerator pedal is serviced as a complete
assembly including the bracket.The accelerator pedal is connected to the upper
part of the accelerator pedal arm by a plastic
retainer (clip) (Fig. 1). This plastic retainer snaps
into the top of the accelerator pedal arm.
(1) From inside the vehicle, hold up accelerator
pedal. Remove plastic cable retainer (clip) and throt-
tle cable core wire from upper end of accelerator
pedal arm (Fig. 1). Plastic cable retainer (clip) snaps
into pedal arm.
(2) Remove 2 accelerator pedal mounting bracket
nuts. Remove accelerator pedal assembly.
KJFUEL INJECTION 14 - 29

OPERATION
2.4L
Engine speed and crankshaft position are provided
through the CKP (Crankshaft Position) sensor. The
sensor generates pulses that are the input sent to the
Powertrain Control Module (PCM). The PCM inter-
prets the sensor input to determine the crankshaft
position. The PCM then uses this position, along with
other inputs, to determine injector sequence and igni-
tion timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
A tonewheel (targetwheel) is a part of the engine
crankshaft (Fig. 4). This tonewheel has sets of
notches at its outer edge.
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM.
3.7L
Engine speed and crankshaft position are provided
through the CKP (Crankshaft Position) sensor. The
sensor generates pulses that are the input sent to the
Powertrain Control Module (PCM). The PCM inter-
prets the sensor input to determine the crankshaft
position. The PCM then uses this position, along with
other inputs, to determine injector sequence and igni-
tion timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.A tonewheel (targetwheel) is bolted to the engine
crankshaft (Fig. 5). This tonewheel has sets of
notches at its outer edge (Fig. 5).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM.
REMOVAL
2.4L
The Crankshaft Position (CKP) sensor is mounted
into the right front side of the cylinder block (Fig. 6).
It is positioned and bolted into a machined hole.
(1) Disconnect sensor electrical connector.
(2) Remove sensor bolt.
(3) Carefully pry sensor from cylinder block in a
rocking action.
(4) Check condition of sensor o-ring (Fig. 7).
3.7L
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block (Fig. 8).
It is positioned and bolted into a machined hole.
(1) Raise vehicle.
(2) Disconnect sensor electrical connector.
(3) Remove sensor mounting bolt (Fig. 8).
(4) Carefully remove sensor from cylinder block in
a rocking and twisting action.
(5) Check condition of sensor o-ring.
Fig. 4 CKP OPERATION-2.4L
1 - NOTCHES
2 - CRANKSHAFT
Fig. 5 CKP OPERATION-3.7L
1 - TONEWHEEL
2 - NOTCHES
3 - CRANKSHAFT POSITION SENSOR
4 - CRANKSHAFT
KJFUEL INJECTION 14 - 31
CRANKSHAFT POSITION SENSOR (Continued)

FUEL INJECTOR
DESCRIPTION
An individual fuel injector (Fig. 9) is used for each
individual cylinder.
OPERATION
OPERATION - FUEL INJECTOR
The top (fuel entry) end of the injector (Fig. 9) is
attached into an opening on the fuel rail.
The fuel injectors are electrical solenoids. The
injector contains a pintle that closes off an orifice at
the nozzle end. When electric current is supplied to
the injector, the armature and needle move a short
distance against a spring, allowing fuel to flow out
the orifice. Because the fuel is under high pressure, a
fine spray is developed in the shape of a pencil
stream. The spraying action atomizes the fuel, add-
ing it to the air entering the combustion chamber.
The nozzle (outlet) ends of the injectors are posi-
tioned into openings in the intake manifold just
above the intake valve ports of the cylinder head.
The engine wiring harness connector for each fuel
injector is equipped with an attached numerical tag
(INJ 1, INJ 2 etc.). This is used to identify each fuel
injector.
The injectors are energized individually in a
sequential order by the Powertrain Control Module(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage is supplied to the injectors through
the ASD relay.
The PCM determines injector pulse width based on
various inputs.
OPERATION - PCM OUTPUT
The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the intake
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.).
This is used to identify each fuel injector with its
respective cylinder number.
The injectors are energized individually in a
sequential order by the Powertrain Control Module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage (12 volts +) is supplied to the injec-
tors through the ASD relay. The ASD relay will shut-
down the 12 volt power source to the fuel injectors if
the PCM senses the ignition is on, but the engine is
not running. This occurs after the engine has not
been running for approximately 1.8 seconds.
The PCM determines injector on-time (pulse width)
based on various inputs.
DIAGNOSIS AND TESTING - FUEL INJECTOR
To perform a complete test of the fuel injectors and
their circuitry, use the DRB scan tool and refer to the
appropriate Powertrain Diagnostics Procedures man-
ual. To test the injector only, refer to the following:
Disconnect the fuel injector wire harness connector
from the injector. The injector is equipped with 2
electrical terminals (pins). Place an ohmmeter across
the terminals. Resistance reading should be approxi-
mately 12 ohms  1.2 ohms at 20ÉC (68ÉF).
Fig. 9 FUEL INJECTOR Ð TYPICAL
KJFUEL INJECTION 14 - 33

REMOVAL
(1) Remove fuel rail. Refer to Fuel Injector Rail
Removal.
(2) Disconnect clip(s) that retain fuel injector(s) to
fuel rail (Fig. 10).
INSTALLATION
(1) Install fuel injector(s) into fuel rail assembly
and install retaining clip(s).
(2) If same injector(s) is being reinstalled, install
new o-ring(s).
(3) Apply a small amount of clean engine oil to
each injector o-ring. This will aid in installation.
(4) Install fuel rail. Refer to Fuel Rail Installation.
(5) Start engine and check for fuel leaks.
FUEL PUMP RELAY
DESCRIPTION
The 5±pin, 12±volt, fuel pump relay is located in
the Power Distribution Center (PDC). Refer to the
label on the PDC cover for relay location.
OPERATION
The Powertrain Control Module (PCM) energizes
the electric fuel pump through the fuel pump relay.
The fuel pump relay is energized by first applying
battery voltage to it when the ignition key is turnedON, and then applying a ground signal to the relay
from the PCM.
Whenever the ignition key is turned ON, the elec-
tric fuel pump will operate. But, the PCM will shut-
down the ground circuit to the fuel pump relay in
approximately 1±3 seconds unless the engine is oper-
ating or the starter motor is engaged.
DIAGNOSIS AND TESTING - FUEL PUMP
RELAY
For procedures, refer to ASD Relay Diagnosis and
Testing in the Ignition section.
REMOVAL
The fuel pump relay is located in the Power Distri-
bution Center (PDC) (Fig. 11). Refer to label on PDC
cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel pump relay is located in the Power Distri-
bution Center (PDC). Refer to label on PDC cover for
relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
Fig. 10 INJECTOR RETAINING CLIP
1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR
4 - FUEL RAIL - TYPICAL
Fig. 11 POWER DISTRIBUTION CENTER (PDC)
1 - BATTERY
2 - PDC
3 - PDC COVER
14 - 34 FUEL INJECTIONKJ
FUEL INJECTOR (Continued)

IDLE AIR CONTROL MOTOR
DESCRIPTION
The IAC stepper motor is mounted to the throttle
body, and regulates the amount of air bypassing the
control of the throttle plate. As engine loads and
ambient temperatures change, engine rpm changes.
A pintle on the IAC stepper motor protrudes into a
passage in the throttle body, controlling air flow
through the passage. The IAC is controlled by the
Powertrain Control Module (PCM) to maintain the
target engine idle speed.
OPERATION
At idle, engine speed can be increased by retract-
ing the IAC motor pintle and allowing more air to
pass through the port, or it can be decreased by
restricting the passage with the pintle and diminish-
ing the amount of air bypassing the throttle plate.
The IAC is called a stepper motor because it is
moved (rotated) in steps, or increments. Opening the
IAC opens an air passage around the throttle blade
which increases RPM.
The PCM uses the IAC motor to control idle speed
(along with timing) and to reach a desired MAP dur-
ing decel (keep engine from stalling).
The IAC motor has 4 wires with 4 circuits. Two of
the wires are for 12 volts and ground to supply elec-
trical current to the motor windings to operate the
stepper motor in one direction. The other 2 wires are
also for 12 volts and ground to supply electrical cur-
rent to operate the stepper motor in the opposite
direction.
To make the IAC go in the opposite direction, the
PCM just reverses polarity on both windings. If only
1 wire is open, the IAC can only be moved 1 step
(increment) in either direction. To keep the IAC
motor in position when no movement is needed, the
PCM will energize both windings at the same time.
This locks the IAC motor in place.
In the IAC motor system, the PCM will count
every step that the motor is moved. This allows the
PCM to determine the motor pintle position. If the
memory is cleared, the PCM no longer knows the
position of the pintle. So at the first key ON, the
PCM drives the IAC motor closed, regardless of
where it was before. This zeros the counter. Fromthis point the PCM will back out the IAC motor and
keep track of its position again.
When engine rpm is above idle speed, the IAC is
used for the following:
²Off-idle dashpot (throttle blade will close quickly
but idle speed will not stop quickly)
²Deceleration air flow control
²A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so
that the engine rpm does not dip down when the
compressor engages)
²Power steering load control
The PCM can control polarity of the circuit to con-
trol direction of the stepper motor.
IAC Stepper Motor Program:The PCM is also
equipped with a memory program that records the
number of steps the IAC stepper motor most recently
advanced to during a certain set of parameters. For
example: The PCM was attempting to maintain a
1000 rpm target during a cold start-up cycle. The last
recorded number of steps for that may have been
125. That value would be recorded in the memory
cell so that the next time the PCM recognizes the
identical conditions, the PCM recalls that 125 steps
were required to maintain the target. This program
allows for greater customer satisfaction due to
greater control of engine idle.
Another function of the memory program, which
occurs when the power steering switch (if equipped),
or the A/C request circuit, requires that the IAC step-
per motor control engine rpm, is the recording of the
last targeted steps into the memory cell. The PCM
can anticipate A/C compressor loads. This is accom-
plished by delaying compressor operation for approx-
imately 0.5 seconds until the PCM moves the IAC
stepper motor to the recorded steps that were loaded
into the memory cell. Using this program helps elim-
inate idle-quality changes as loads change. Finally,
the PCM incorporates a9No-Load9engine speed lim-
iter of approximately 1800 - 2000 rpm, when it rec-
ognizes that the TPS is indicating an idle signal and
IAC motor cannot maintain engine idle.
A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate.Never attempt to adjust the engine idle
speed using this screw.All idle speed functions are
controlled by the IAC motor through the PCM.
KJFUEL INJECTION 14 - 35

REMOVAL
2.4L
The Idle Air Control (IAC) motor is located on the
rear side of the throttle body (Fig. 12).
(1) Disconnect electrical connector from IAC motor.
(2) Remove two mounting bolts (screws).
(3) Remove IAC motor from throttle body.
3.7L
The Idle Air Control (IAC) motor is located on the
side of the throttle body (Fig. 13).
(1) Disconnect electrical connector from IAC motor.
(2) Remove two mounting bolts (screws).
(3) Remove IAC motor from throttle body.
INSTALLATION
2.4L
The Idle Air Control (IAC) motor is located on the
rear side of the throttle body.
(1) Install IAC motor to throttle body.
(2) Install and tighten two mounting bolts (screws)
to 7 N´m (60 in. lbs.) torque.
(3) Install electrical connector.
3.7L
The Idle Air Control (IAC) motor is located on the
side of the throttle body (Fig. 13).
(1) Install IAC motor to throttle body.(2) Install and tighten two mounting bolts (screws)
to 7 N´m (60 in. lbs.) torque.
(3) Install electrical connector.
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The 2±wire Intake Manifold Air Temperature (IAT)
sensor is installed in the intake manifold with the
sensor element extending into the air stream.
The IAT sensor is a two-wire Negative Thermal
Coefficient (NTC) sensor. Meaning, as intake mani-
fold temperature increases, resistance (voltage) in the
sensor decreases. As temperature decreases, resis-
tance (voltage) in the sensor increases.
OPERATION
The IAT sensor provides an input voltage to the
Powertrain Control Module (PCM) indicating the
density of the air entering the intake manifold based
upon intake manifold temperature. At key-on, a
5±volt power circuit is supplied to the sensor from
the PCM. The sensor is grounded at the PCM
through a low-noise, sensor-return circuit.
The PCM uses this input to calculate the following:
²Injector pulse-width
²Adjustment of spark timing (to help prevent
spark knock with high intake manifold air-charge
temperatures)
Fig. 12 TPS/IAC MOTOR - 2.4L
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
Fig. 13 TPS/IAC MOTOR - 3.7L
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
14 - 36 FUEL INJECTIONKJ
IDLE AIR CONTROL MOTOR (Continued)