2002 JEEP LIBERTY Crankshaft

DESCRIPTION SPECIFICATION
Valve Springs
Free Length (Approx.) 48.4 mm
(1.905 in.)
Nominal Force (Valve
Closed)338 N @ 38.0 mm
(75.98 lbs. @ 1.496 in.)
Nominal Force (Valve
Open)607 N @ 29.75 mm
(136 lbs. @ 1.172 in.)
Installed Height 38.00 mm
(1.496 in.)
Number of Coils 7.82
Wire Diameter 3.86 mm
(1.496 in.)
Oil Pump
Clearance Over Rotors
(Max.)0.10 mm
(0.004 in.)
Cover Out-of-Flat (Max.) 0.025 mm
(0.001 in.)
Inner Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Clearance
(Max.)0.039 mm
(0.015 in.)
Outer Rotor Diameter
(Min.)79.95 mm
(3.148 in.)
Tip Clearance Between
Rotors (Max.)0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed* 25 kPa
(4 psi)
At 3000 rpm 170±550 kPa
(25±80 psi)
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.SPECIFICATIONS - TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts54 +
1¤4
turn40
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 34 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Flywheel Mounting Bolts 81 60 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
Exhaust Manifold to
Cylinder HeadÐBolts23 Ð 200
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Oil Filter 20 15 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pump to BlockÐBolts 28 Ð 250
9s - 16 ENGINEKJ
ENGINE - 2.4L (Continued)

DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 20 Ð
Oil Pump Relief
ValveÐCap41 30
Spark Plugs 28 Ð
Timing Belt Covers
- Front Covers to Rear
CoverÐBolts12 Ð 105
- Rear CoverÐBolts 12 Ð 105
Timing Belt Tensioner
AssemblyÐBolts61 45 Ð
SPECIAL TOOLS
2.4L ENGINE
Puller 1026
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Holder 6847
Camshaft Seal Remover C-4679-A
Camshaft Seal Installer MD-998306
Crankshaft Damper Installer 6792
Valve Spring Compressor 8215
Adaptor 8436
KJENGINE9s-17
ENGINE - 2.4L (Continued)

Valve Spring Compressor MD-998772-A
Valve Spring Compressor Adapter 6779
Cylinder Bore Gage C-119
Crankshaft Sprocket Remover 6793
Crankshaft Sprocket Remover Insert C-4685-C2
Crankshaft Seal Remover 6771
Oil Pressure Gage C-3292
Rear Crankshaft Seal Guide and Installer 6926-1 and
6926-2
Balance Shaft Sprocket Installer 6052
Front Crankshaft Oil Seal Installer 6780
9s - 18 ENGINEKJ
ENGINE - 2.4L (Continued)

(3) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
NOTE: Target ring tab should provide posative
snap-on fit on the camshaft.
(4) Install exhaust camshaft target ring with the
wordFRONTfacing forward.
(5) Install exhaust camshaft sensor.
(6) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.).
(7) Install timing belt and front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAINAND SPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
CAMSHAFT(S)
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 15).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the exhaust camshaft on the front of the cylinder
head. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
STANDARD PROCEDURE - CAMSHAFT
END-PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTcam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 16).
(4) Move camshaft as far forward as it will go.
(5) Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
(6) If end play is excessive, check cylinder head
and camshaft for wear; replace as necessary.
Fig. 12 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 13 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
Fig. 14 Camshaft Seal - Installation
1 - SPECIAL TOOL MD 998306
KJENGINE9s-23
CAMSHAFT OIL SEAL(S) (Continued)

(4) Install cylinder head cover assembly to cylin-
der head. Install all bolts, ensuring the two (2) bolts
containing the sealing washer are located in the cen-
ter locations of cover. Tighten bolts in sequence
shown in (Fig. 25). Using a 3 step torque method as
follows:
(a) Tighten all bolts to 4.5 N´m (40 in. lbs.).
(b) Tighten all bolts to 9.0 N´m (80 in. lbs.).
(c) Tighten all bolts to 12 N´m (105 in. lbs.).
(5) Install intake manifold.
(6) Install ignition coil and spark plug wires.
Tighten fasteners to 12 N´m (105 in. lbs.).
(7) If the PCV valve was removed, apply Mopart
Thread Sealant with Teflon to threads and install
valve to cylinder head cover. Tighten PCV valve to 8
N´m (70 in. lbs.).
(8) Connect PCV and make-up air hoses to cylin-
der head cover.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The four valves per cylinder are opened by using
roller rocker arms which pivot on hydraulic lash
adjusters. The valves have chrome plated valve
stems. Viton rubber valve stem seals are integral
with the spring seats.They have chrome plated stems
to prevent scuffing. Viton rubber valve stem seals are
integral with the spring seats. The valves, spring
retainers,and locks, are the 3 - bead lock design
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
VALVE SPRINGS
REMOVAL
REMOVAL - CYLINDER HEAD ON
(1) Remove camshafts.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772-A with adapter
6779 (Fig. 26), compress valve springs and remove
valve locks.
(5) Remove valve spring(s).
(6) Remove valve stem seal(s) by a using valve
stem seal tool (Fig. 28).
REMOVAL - CYLINDER HEAD OFF
(1) With cylinder head removed from cylinder
block, compress valve springs using a universal valve
spring compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves, locks and
retainers to insure installation in original location.
(4) Inspect the valves. (Refer to 9 - ENGINE/CYL-
INDER HEAD/VALVE SPRINGS - INSPECTION)
Fig. 25 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 26 Valve Spring - Removal/Installation
1 - VALVE SPRING COMPRESSOR MD 998772A
2 - AIR HOSE
KJENGINE9s-27
CYLINDER HEAD COVER (Continued)

CAUTION: If cam follower assemblies are to be
reused, always mark position for reassembly in
their original positions.
(5) Using Special Tools 8215 and 8436 slowly
depress valve assembly until rocker arm can be
removed (Fig. 31).
NOTE: It may be necessary to remove additional
brackets or components to allow clearance for tool
handle movement.
(6) Repeat removal procedure for each rocker arm.
INSPECTION
Inspect the rocker arm for wear or damage (Fig.
32). Replace as necessary.
INSTALLATION
(1) Lubricate rocker arm with clean engine oil.
(2) Using Special Tools 8215 and 8436 slowly
depress valve assembly until rocker arm can be
installed on the hydraulic lifter and valve stem.
(3) Repeat installation procedure for each rocker
arm.
(4) Install spark plugs.
(5) Install fuel rail. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION)
(6) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ENGINE BLOCK
DESCRIPTION
The cast iron cylinder block is a two-piece assem-
bly, consisting of the cylinder block and bedplate (Fig.
33). The bedplate incorporates the main bearing caps
and bolts to the cylinder block. This design offers a
much stronger lower end and increased cylinder
block rigidity. The rear oil seal retainer is integral
with the block. The bedplate and block are serviced
as an assembly.
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin about 14 mm (9/16 inch.) from the bottom
of the skirt as shown in (Fig. 35). Cylinder bores
should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center line
Fig. 31 Rocker Arm - Removal/Installation
1 - SPECIAL TOOL 8215
2 - ROCKER ARM
3 - SPECIAL TOOL 8436
Fig. 32 Rocker Arm - Typical
1 - TIP
2 - LASH ADJUSTER POCKET
3 - ROLLER
Fig. 33 2.4L Cylinder Block and Bedplate - Typical
1 - CYLINDER BLOCK
2 - BEDPLATE
9s - 30 ENGINEKJ
ROCKER ARMS (Continued)

INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
37) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 37). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
(1) For measuring connecting rod bearing clear-
ance procedure and use of Plastigage(Refer to 9 -
ENGINE - STANDARD PROCEDURE). For bearing
clearance refer to Engine Specifications. (Refer to 9 -
ENGINE - SPECIFICATIONS)
NOTE: The rod bearing bolts should not be reused.
(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 38). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 39). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
Fig. 37 Checking Cylinder Bore Size
Fig. 38 Connecting Rod Side Clearance
9s - 32 ENGINEKJ
ENGINE BLOCK (Continued)

OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 40).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Remove flex plate and crankshaft rear oil seal.
(3) Mount engine on a repair stand.
(4) Drain engine oil and remove oil filter.
(5) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(6) Remove the timing belt covers. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)(7) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(8) Remove the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL)
(9) Remove balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
(10) Remove all bedplate bolts from the engine
block (Fig. 41).
(11) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(12) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
(13) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
Fig. 39 Crankshaft - Typical
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 40 CHECKING CRANKSHAFT END PLAY
Fig. 41 Bedplate Bolt Tightenening Sequence
KJENGINE9s-33
CRANKSHAFT (Continued)