2002 JEEP LIBERTY Engine removal

(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 45).
(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 46).INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Using Special Tool 8348 and 8512, install
crankshaft front seal (Fig. 47).
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(3) Install radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(4) Install upper radiator hose.
(5) Install A/C compressor and tighten fasteners to
54 N´m (40 ft. lbs.).
(6) Install accessory drive belt refer (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect negative cable to battery.
Fig. 45 Crankshaft DamperÐRemoval
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 46 Crankshaft Front SealÐRemoval
1 - SPECIAL TOOL 8511
Fig. 47 Crankshaft Front SealÐInstallation
1 - TIMING CHAIN COVER
2 - SPECIAL TOOL 8348
3 - SPECIAL TOOL 8512
KJENGINE - 3.7L 9 - 47
CRANKSHAFT OIL SEAL - FRONT (Continued)

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506 (Fig. 48), remove the
crankshaft rear oil seal.
INSTALLATION
(1) Position the magnetic seal guide Special Tool
8349±2 (Fig. 49) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle (Fig. 50),
with a hammer, tap the seal into place. Continue to
tap on the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) Install the transmission.
Fig. 48 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8506
Fig. 49 Crankshaft Rear Oil Seal Guide Special Tool
8349±2 and Oil
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349±2 GUIDE
Fig. 50 Crankshaft Rear Oil Seal Installation
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349±1 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
9 - 48 ENGINE - 3.7LKJ

FLEX PLATE
REMOVAL
(1) Remove the transmission.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 95 N´m
(70 ft. lbs.) in the sequence shown (Fig. 51).
(3) Install the transmission.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pistons are made of a high strength aluminum
alloy. The top ring groove is coated with a anti-seize
coating. The connecting rods are made of forged pow-
dered metal, with a ªfractured capº design. A full
floating piston pin is used to attach the piston to the
connecting rod (Fig. 52).
1 Connecting Rod
2 Piston
3 Piston Pin
4 Oil Slinger Slot
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING
Inspect the connecting rod bearings for scoring and
bent alignment tabs. Check the bearings for normal
wear patterns, scoring, grooving, fatigue and pitting.
Replace any bearing that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
necting rod journals. If wear patterns or damage to
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
(1) Wipe the oil from the connecting rod journal.
(2) Lubricate the upper bearing insert and install
in connecting rod.
(3) Use piston ring compressor and Guide Pins
Special Tool 8507 to install the rod and piston assem-
blies. The oil slinger slots in the rods must face front
of the engine. The ªFº's near the piston wrist pin
bore should point to the front of the engine.
(4) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
(5) Install bearing cap and connecting rod on the
journal and tighten bolts to 27 N´m (20 ft. lbs.) plus a
Fig. 51 Flexplate Tightening Sequence
1 - FLEXPLATE
Fig. 52 PISTON AND ROD ASSEMBLY
KJENGINE - 3.7L 9 - 49

90É turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage. Refer to Engine
Specifications for the proper clearance.Plastigage
should indicate the same clearance across the
entire width of the insert. If the clearance var-
ies, it may be caused by either a tapered jour-
nal, bent connecting rod or foreign material
trapped between the insert and cap or rod.
(7) If the correct clearance is indicated, replace-
ment of the bearing inserts is not necessary. Remove
the Plastigage from crankshaft journal and bearing
insert. Proceed with installation.
(8) If bearing-to-journal clearance exceeds the
specification, determin which services bearing set to
use the bearing sizes are as follows:
Bearing
MarkSIZE USED WITH
JOURNAL SIZE
.025 US.025 mm 57.871-57.879 mm
(.001 in.) (2.2783-2.2786 in.)
Std.STANDARD 57.896-57.904 mm
(2.2793-2.2810 in.)
.250 US.250 mm 57.646-57.654 mm
(.010 in.) (2.2695-2.2698 in.)
(9) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(10) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 27 N´m (20 ft. lbs.) plus a 90É turn.
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange. Refer to
Engine Specifications for the proper clearance.
Replace the connecting rod if the side clearance is
not within specification.
STANDARD PROCEDURE - PISTON FITTING
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm (
.0001 in.) INCREMENTS is required. If a bore gauge
is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at a point 38.0 mm (1.5 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then take
an additional bore reading 90 degrees to that at point
B (Fig. 54).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled.(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 53). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
(5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fit
with the cylinder bore.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components:
²Oil pan and gasket/windage tray (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
²Timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL).
²Cylinder head(s) (Refer to 9 - ENGINE/CYLIN-
DER HEAD - REMOVAL) and (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) If necessary, remove top ridge of cylinder bores
with a reliable ridge reamer before removing pistons
from cylinder block.Be sure to keep tops of pis-
tons covered during this operation.Pistons and
connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod
Fig. 53 Moly Coated Piston - Typical
1 - MOLY COATED
2 - MOLY COATED
9 - 50 ENGINE - 3.7LKJ
PISTON & CONNECTING ROD (Continued)

assemblies from the engine, rotate crankshaft so the
each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecting rod and bearing cap positions
using a permanent ink marker or scribe tool.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecting rod cap. Install Special Tool
8507 Connecting Rod Guides into the connecting rod
being removed. Remove piston from cylinder bore.
Repeat this procedure for each piston being removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) Immediately after piston and connecting rod
removal, install bearing cap on the mating connect-
ing rod to prevent damage to the fractured cap and
rod surfaces.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Using a suitable cleaning solvent clean the pis-
tons in warm water and towel dry.
(2) Use a wood or plastic scraper to clean the ring
land grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape
before it is fitted into the cylinder bore (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in
the piston skirts. Check the ring lands for cracks
and/or deterioration.
INSTALLATION
(1) Before installing piston and connecting rod
assemblies into the bore, install the piston rings.
(2) Immerse the piston head and rings in clean
engine oil. Position a ring compressor over the piston
and rings. Tighten ring compressor.Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Position bearing onto connecting rod. Ensure
that tabs in bearing shell aligns with slots in con-
necting rod. Verify that parting line of bearing is
aligned with parting line of connecting rod.
(4) Lubricate bearing surface with clean engine oil.
(5) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads (Fig. 55).
(6) The pistons are marked on the piston pin bore
surface with an raised ªFº indicating installation
position. This mark must be pointing toward the
front of engine on both cylinder banks. The connect-
ing rod oil slinger slot faces the front of the engine
(Fig. 56).
(7) Wipe cylinder bore clean and lubricate with
engine oil.
(8) Rotate crankshaft until connecting rod journal
is on the center of cylinder bore. Insert rod and pis-
Fig. 54 Bore Gauge - Typical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
KJENGINE - 3.7L 9 - 51
PISTON & CONNECTING ROD (Continued)

VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(3) Remove crankshaft damper bolt.
(4) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 62).
Fig. 59 Side RailÐInstallation
1 - SIDE RAIL END
Fig. 60 Upper and Intermediate RingsÐInstallation
Fig. 61 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 62 Crankshaft DamperÐRemoval
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
9 - 54 ENGINE - 3.7LKJ
PISTON RINGS (Continued)

INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Align crankshaft damper slot with key in
crankshaft. Slide damper onto crankshaft slightly.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assemble Special Tool 8512±A as follows, The
nut is threaded onto the shaft first. Then the roller
bearing is placed onto the threaded rod (The hard-
ened bearing surface of the bearingMUSTface the
nut). Then the hardened washer slides onto the
threaded rod (Fig. 63). Once assembled coat the
threaded rod's threads with MopartNickel Anti-
Seize or (Loctite No. 771).
(3) Using Special Tool 8512A, press damper onto
crankshaft (Fig. 64).
(4) Install then tighten crankshaft damper bolt to
175 N´m (130 ft. lbs.).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Connect negative cable to battery.
STRUCTURAL COVER
DESCRIPTION
The structural dust cover is made of die cast alu-
minum and joins the lower half of the transmission
bell housing to the engine bedplate.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the bolts retaining structural cover
(Fig. 65).
(3) Remove the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all bolts retaining the cover-to-engine.
DO NOT tighten the bolts at this time.
(3) Install the cover-to-transmission bolts. Do NOT
tighten at this time.
Fig. 63 Proper Assembly Method for Special Tool
8512±A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 64 Crankshaft Damper Installation
1 - SPECIAL TOOL 8512A
KJENGINE - 3.7L 9 - 55
VIBRATION DAMPER (Continued)

CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 66) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 66) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
FRONT MOUNT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the fan blade, fan clutch and fan
shroud. Refer to COOLING SYSTEM for procedure.
(3) Remove the engine oil filter.
(4) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(5) Remove the four (4) cylinder block-to-insulator
mount bolts and the nut from the engine insulator
mount through bolt.
(6) Using the jack, raise the engine high enough to
remove the engine insulator mount through bolt and
the insulator mount (Fig. 67) and (Fig. 68).
Fig. 65 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 66 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 67 Engine Insulator Mount 3.7 Left
1 -MOUNT
2 - NUT
3 - WIRE RETAINER
4 - FASTENER
5 - BOLT
6 - THRU BOLT
9 - 56 ENGINE - 3.7LKJ
STRUCTURAL COVER (Continued)