2002 JEEP LIBERTY Throttle body

mounting bracket displayed in (Fig. 6) is a typical
bracket and may/may not be applicable to this model
vehicle.
(9) Remove servo from mounting bracket. While
removing, note orientation of servo to bracket.INSTALLATION
(1) Position servo to mounting bracket.
(2) Align hole in cable connector with hole in servo
pin. Install cable-to-servo retaining clip.
(3) Insert servo mounting studs through holes in
servo mounting bracket.
(4) Install servo-to-mounting bracket nuts and
tighten. Refer to torque specifications.
(5) Install servo mounting bracket-to-body nuts
and tighten. Refer to torque specifications.
(6) Connect vacuum line at servo.
(7) Connect electrical connector at servo.
(8) Connect servo cable to throttle body. Refer to
servo Cable Removal/Installation.
(9) Install coolant bottle.
(10) Connect negative battery cable to battery.
(11) Before starting engine, operate accelerator
pedal to check for any binding.
SWITCH
DESCRIPTION
There are two separate switch pods that operate
the speed control system. The steering-wheel-
mounted switches use multiplexed circuits to provide
inputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owner's manual for more information on speed
control switch functions and setting procedures.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
OPERATION
When speed control is selected by depressing the
ON, OFF switch, the PCM allows a set speed to be
stored in its RAM for speed control. To store a set
speed, depress the SET switch while the vehicle is
moving at a speed between approximately 35 and 85
mph. In order for the speed control to engage, the
brakes cannot be applied, nor can the gear selector
be indicating the transmission is in Park or Neutral.
The speed control can be disengaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
The speed control can be disengaged also by any of
the following conditions:
²An indication of Park or Neutral
²The VSS signal increases at a rate of 10 mph
per second (indicates that the co-efficient of friction
between the road surface and tires is extremely low)
²Depressing the clutch pedal.
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear)
Fig. 5 SPEED CONTROL SERVO
1-9T9FITTING
2 - VACUUM LINE
3 - SERVO BRACKET MOUNTING NUTS
4 - SERVO MOUNTING BRACKET
5 - SERVO
6 - SERVO ELECTRICAL CONNECTOR
Fig. 6 SERVO CABLE CLIP REMOVE/INSTALL
TYPICAL
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
KJSPEED CONTROL 8P - 5
SERVO (Continued)

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8Wa-30-34
A/C Compressor Clutch Relay..... 8Wa-30-34, 2, 3
A/C High Pressure Switch............ 8Wa-30-29
A/C Low Pressure Switch.......... 8Wa-30-8, 29
A/C Pressure Transducer....... 8Wa-30-11, 23, 12
Accelerator Pedal Position Sensor...... 8Wa-30-27
Auto Shut Down Relay . . 8Wa-30-13, 14, 15, 24, 28,
31, 16, 17, 2
Battery Temperature Sensor........ 8Wa-30-30, 7
Blower Motor Relay................. 8Wa-30-31
Body Control Module.............. 8Wa-30-8, 33
Boost Pressure Sensor............ 8Wa-30-26, 28
Brake Lamp Switch............ 8Wa-30-8, 32, 33
Cabin Heater...................... 8Wa-30-34
Cabin Heater Relay................. 8Wa-30-34
Camshaft Position Sensor....... 8Wa-30-10, 9, 28
Capacitor...................... 8Wa-30-19, 17
Clockspring..................... 8Wa-30-33, 7
Clutch Switch Override Relay.... 8Wa-30-13, 8, 32
Coil On Plug No. 1................. 8Wa-30-19
Coil On Plug No. 2................. 8Wa-30-20
Coil On Plug No. 3................. 8Wa-30-19
Coil On Plug No. 4................. 8Wa-30-20
Coil On Plug No. 5................. 8Wa-30-19
Coil On Plug No. 6................. 8Wa-30-20
Coil Rail......................... 8Wa-30-17
Controller Antilock Brake............ 8Wa-30-33
Crankshaft Position Sensor...... 8Wa-30-10, 9, 27
Data Link Connector.............. 8Wa-30-25, 6
Diagnostic Junction Port........... 8Wa-30-25, 6
EGR Solenoid..................... 8Wa-30-30
Engine Control Module . . 8Wa-30-24, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34, 35, 36
Engine Coolant Temperature Sensor . 8Wa-30-11, 28,
12
Engine Oil Pressure Sensor..... 8Wa-30-11, 28, 12
Evap/Purge Solenoid................. 8Wa-30-2
Fuel Heater....................... 8Wa-30-31
Fuel Heater Relay.................. 8Wa-30-31
Fuel Injector No. 1............... 8Wa-30-18, 36
Fuel Injector No. 2............... 8Wa-30-18, 36
Fuel Injector No. 3............... 8Wa-30-18, 36
Fuel Injector No. 4............... 8Wa-30-18, 36
Fuel Injector No. 5................. 8Wa-30-18
Fuel Injector No. 6................. 8Wa-30-18
Fuel Pressure Sensor............... 8Wa-30-36
Fuel Pressure Solenoid.............. 8Wa-30-31
Fuel Pump Module............. 8Wa-30-30, 4, 5
Fuel Pump Relay.............. 8Wa-30-4, 2, 3, 5
Fuse 2........................... 8Wa-30-23
Fuse 6................... 8Wa-30-24, 28, 31, 2Component Page
Fuse 10.......................... 8Wa-30-35
Fuse 11.......................... 8Wa-30-35
Fuse 12....................... 8Wa-30-31, 33
Fuse 15...................... 8Wa-30-25, 2, 3
Fuse 16...... 8Wa-30-13, 14, 15, 24, 30, 34, 35, 16
Fuse 21.......................... 8Wa-30-34
Fuse 24...................... 8Wa-30-31, 2, 3
Fuse 26.................. 8Wa-30-18, 24, 17, 2
Fuse 28.......................... 8Wa-30-13
G100.................... 8Wa-30-19, 27, 17, 3
G101............................ 8Wa-30-23
G103................. 8Wa-30-15, 23, 31, 34, 16
G104............................ 8Wa-30-27
G111 ............................ 8Wa-30-31
G112 .......................... 8Wa-30-8, 23
G320........................... 8Wa-30-4, 5
Generator.................. 8Wa-30-24, 4, 3, 5
Glow Plug Assembly................ 8Wa-30-35
Glow Plug Relay No. 1.............. 8Wa-30-35
Glow Plug Relay No. 2.............. 8Wa-30-35
Idle Air Control Motor............ 8Wa-30-21, 22
Ignition Switch.................... 8Wa-30-32
Intake Air Temperature Sensor..... 8Wa-30-11, 12
Junction Block........... 8Wa-30-25, 31, 33, 2, 3
Knock Sensor...................... 8Wa-30-8
Leak Detection Pump.............. 8Wa-30-4, 5
Left Speed Control Switch.......... 8Wa-30-33, 7
Manifold Absolute Pressure Sensor . . 8Wa-30-11, 12
Oxygen Sensor 1/1 Upstream...... 8Wa-30-14, 15
Oxygen Sensor 1/2 Downstream . 8Wa-30-13, 14, 15
Oxygen Sensor 2/1 Upstream......... 8Wa-30-16
Oxygen Sensor 2/2 Downstream.... 8Wa-30-13, 16
Oxygen Sensor Downstream Relay . . 8Wa-30-13, 15,
16
Power Distribution Center . . 8Wa-30-13, 14, 15, 23,
24, 28, 30, 31, 34, 35, 16, 17, 2, 3
Power Steering Pressure Switch....... 8Wa-30-23
Powertrain Control Module . . . 8Wa-30-10, 13, 20, 8,
11, 14, 15, 18, 19, 21, 9, 23, 4, 12, 16, 17, 2, 22, 3,
6, 7, 5
Radiator Fan Motor................. 8Wa-30-23
Radiator Fan Relay................. 8Wa-30-23
Right Speed Control Switch......... 8Wa-30-33, 7
Shifter Assembly................. 8Wa-30-8, 32
Speed Control Servo................. 8Wa-30-8
Starter Motor Relay................ 8Wa-30-13
Throttle Position Sensor.......... 8Wa-30-21, 22
Transfer Case Position Sensor.... 8Wa-30-9, 23, 32
Transmission Control Module . . 8Wa-30-10, 8, 22, 6
Transmission Solenoid/Trs Assembly.... 8Wa-30-10
Water In Fuel Sensor............... 8Wa-30-29
KJ8W-30 FUEL/IGNITION SYSTEM8Wa-30-1

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Front Wiper Motor (RHD) BK Right Side of Cowl 24
Fuel Heater (Diesel) BK Left Rear Side of Engine
Compartment19
Fuel Injector No.1 (Diesel) BK At Fuel Injector 23
Fuel Injector No.1 (Gas) BK At Fuel Injector 1
Fuel Injector No.2 (Diesel) BK At Fuel Injector 23
Fuel Injector No.2 (Gas) BK At Fuel Injector 2
Fuel Injector No.3 (Diesel) BK At Fuel Injector 23
Fuel Injector No.3 (Gas) BK At Fuel Injector 1
Fuel Injector No.4 (Diesel) BK At Fuel Injector 22
Fuel Injector No.4 (Gas) BK At Fuel Injector 2
Fuel Injector No.5 (3.7L) BK At Fuel Injector 1
Fuel Injector No.6 (3.7L) BK At Fuel Injector 2
Fuel Pressure Sensor (Diesel) Left Side of Engine 22
Fuel Pressure Solenoid (Diesel) BK Left Side of Engine 20
Fuel Pump Module LG At Fuel Tank N/S
Generator BK Left Front Side of Engine 20
Glow Plug Assembly (Diesel) Top of Engine N/S
Headlamp Leveling Switch (BUX) BK Center of Instrument Panel N/S
Heated Seat Module (Highline) GN At Left Seat N/S
High Note Horn BK Left Front Side of Engine
Compartment29
Hood Ajar Switch Right Side of Engine
Compartment25
Idle Air Control Motor BK On Throttle Body 1
Ignition Switch At Steering Column N/S
Input Speed Sensor (3.7L) BK Left Side of Transmission 5
Instrument Cluster BK Rear of Cluster N/S
Intake Air Temperature Sensor GY Left Side of Intake Manifold 1
Intrusion Sensor (BUX) BK Overhead Console N/S
Junction Block Body Control Module -
JBUnder Left Side of
Instrument PanelN/S
Junction Block C1 GY Under Left Side of
Instrument PanelN/S
Junction Block C2 GN Under Left Side of
Instrument PanelN/S
Junction Block C3 LB Under Left Side of
Instrument PanelN/S
Knock Sensor (3.7L) BK Near Fuel Injector No.5 1
Leak Detection Pump BK Near Fuel Tank N/S
Left Curtain Airbag YL Left Mid B-Pillar 35, 38
Left Cylinder Lock Switch LG In Left Front Door 41
Left Door Lock Switch BK In Left Front Door 41
Left Fog Lamp BK Left Side of Front Bumper N/S
KJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION8Wa-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Siren (BUX) Right Front Side of Engine
Compartment28
Speed Control Servo BK Right Rear Side of Engine
Compartment27
Sunroof Motor LG Overhead Console N/S
Sunroof Switch BK Overhead Console N/S
Tailgate Cylinder Lock Switch LG In Tailgate 46
Tailgate Flip-Up Ajar Switch GY In Tailgate 46
Tailgate Lock Motor/Ajar Switch BK In Tailgate 46
Throttle Position Sensor WT On Throttle Body 1
Trailer Tow Brake Lamp Relay Right Quarter Panel 47
Trailer Tow Circuit Breaker Right Quarter Panel N/S
Trailer Tow Connector BK At Trailer Hitch 47, 48
Trailer Tow Right Turn Relay Right Quarter Panel 47
Trailer Tow Relay Right Quarter Panel 47
Trailer Tow Left Turn Relay Right Quarter Panel 47
Transfer Case Position Sensor BK Rear Side of Transmission 5, 7, 11, 12, 22
Transmission Control Module (3.7L)
(LHD)BK Right Rear Side of Engine
Compartment8, 9
Transmission Control Module (3.7L)
(RHD)BK Left Rear Side of Engine
Compartment10
Transmission Solenoid/TRS
Assembly (3.7L)GY Left Side of Transmission 5
Under Hood Lamp BK Underside of Hood 24
Washer Fluid Level Switch LG At Washer Fluid Reservoir 28
Water In Fuel Sensor (Diesel) Left Rear Side of Engine
Compartment19
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Left Side of Engine Compartment 8, 9, 10, 14, 19
G101 (2.4L) Left Side of Engine Compartment 11
G102 (LHD) Right Rear Side of Engine Compartment 9
G102 (RHD) Left Rear Side of Engine Compartment 10
G103 (3.7L) Right Front Side of Engine 4
G103 (Diesel) Right Front Side of Engine 20
G104 Near Engine Control Module C2 19
G105 Left Side of Engine Compartment N/S
G106 Left Side of Engine Compartment N/S
G110 Left Side of Engine Compartment 30
G111 Left Front Side of Engine Compartment 29
G112 Left Front Side of Engine Compartment 29
G200 Near Body Control Module N/S
KJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION8Wa-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
5. Leaking valve guide seals. 5. Replace valve guide seals.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disable the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRI-
CAL/IGNITION CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(7) Record the compression pressure on the 3rd
revolution. Continue the test for the remaining cylin-
ders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for
the correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
(1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains
normal operating temperature, then turn the engine
OFF.
(3) Remove the spark plugs.
(4) Remove the oil filler cap.
(5) Remove the air cleaner.
(6) Calibrate the tester according to the manufac-
turer's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
(7) Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
Set piston of cylinder to be tested at TDC compres-
sion,While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART .
9 - 8 ENGINE - 3.7LKJ
ENGINE - 3.7L (Continued)

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 1)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 1)
²Drill motor with 3M RolocŸ Bristle Disc (white
or yellow) (Fig. 1)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
Fig. 1 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOCŸ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
KJENGINE - 3.7L 9 - 9
ENGINE - 3.7L (Continued)

²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove hood. Mark hood hinge location for
reinstallation.
(3) Remove air cleaner assembly.(4) Remove radiator core support bracket.
(5) Remove fan shroud with electric fan assembly.
(6) Remove mechanical cooling fan.
(7) Remove drive belt.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(8) Remove A/C compressor and secure away from
engine with lines attached.
(9) Remove generator and secure away from
engine.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(10) Remove power steering pump with lines
attached and secure away from engine.
(11) Drain cooling system.
(12) Remove coolant bottle.
(13) Disconnect the heater hoses from the engine.
(14) Disconnect heater hoses from heater core and
remove hose assembly.
(15) Disconnect throttle and speed control cables.
(16) Remove upper radiator hose from engine.
(17) Remove lower radiator hose from engine.
(18) Disconnect the engine to body ground straps
at the left side of cowl.
(19) Disconnect the engine wiring harness at the
following points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(20) Remove coil over plugs.
(21) Release fuel rail pressure.
(22) Remove fuel rail and secure away from
engine.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(23) Remove the PCV hose.
(24) Remove the breather hoses.
(25) Remove the vacuum hose for the power brake
booster.
(26) Disconnect knock sensors.
(27) Remove engine oil dipstick tube.
(28) Remove intake manifold.
(29) Install engine lift plate.
Fig. 2 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 10 ENGINE - 3.7LKJ
ENGINE - 3.7L (Continued)

NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(30) Secure the left and right engine wiring har-
nesses away from engine.
(31) Raise vehicle.
(32) Disconnect oxygen sensor wiring.
(33) Disconnect crankshaft postion sensor.
(34) Disconnect the engine block heater power
cable, if equipped.
(35) Disconnect the front propshaft at the front
differential and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.
(36) Remove the starter.
(37) Remove the ground straps from the left and
right side of the block.
(38) Disconnect the right and left exhaust pipes at
the manifolds and from the crossover, and remove
from the vehicle.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
NOTE: For manual transmission vehicles, the trans-
mission must be removed from the vehicle, before
the engine can be removed. The manual transmis-
sion will contact the floorpan before the engine
clears the motor mounts, so it must be removed.
(39) Remove the structural cover.
(40) Remove torque convertor bolts, and mark
location for reassembly.
(41) Remove transmission bellhousing to engine
bolts.
(42) Loosen left and right engine mount thru bolts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(43) Lower the vehicle.
(44) Support the transmission with a suitable jack.
(45) Connect a suitable engine hoist to the engine
lift plate.
(46) Remove engine from vehicle.
INSTALLATION
(1) Position the engine in the vehicle.
(2) Install both left and right side engine mounts
onto engine.
(3) Raise the vehicle.(4) Install the transmission bellhousing to engine
mounting bolts. Tighten the bolts to 41 N´m (30ft.
lbs.).
(5) Tighten the engine mount thru bolts.
(6) Install the torque convertor bolts.
(7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter.
(9) Connect the crankshaft position sensor.
(10) Install the engine block heater power cable, if
equipped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) Install the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) Install the left and right exhaust pipes.
(13) Connect the left and right oxygen sensors.
(14) Lower vehicle.
(15) Remove the engine lift plate.
(16) Connect the knock sensors.
(17) Connect the engine to body ground straps at
the left side of the cowl.
(18) Install the intake manifold.
(19) Install the engine oil dipstick tube.
(20) Install the power brake booster vacuum hose.
(21) Install the breather hoses.
(22) Install the PCV hose.
(23) Install the fuel rail.
(24) Install the coil over plugs.
(25) Connect the engine wiring harness at the fol-
lowing points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(26) Connect lower radiator hose.
(27) Connect upper radiator hose.
(28) Connect throttle and speed control cables.
(29) Install the heater hose assembly.
(30) Install coolant recovery bottle.
(31) Install the power steering pump.
(32) Install the generator.
(33) Install the A/C compressor.
(34) Install the drive belt.
KJENGINE - 3.7L 9 - 11
ENGINE - 3.7L (Continued)