2002 JEEP LIBERTY Timing cover

(9) Remove the accessory drive bracket.
(10) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- REMOVAL).
(11) Remove timing belt idler pulley.
(12) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(13) Remove the timing belt rear cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(14) Remove water pump to engine attaching
screws (Fig. 15).
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION - 2.4L ENGINE
(1) Install new O-ring gasket in water pump body
O-ring locating groove (Fig. 16).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may be damaged and
cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 103.4 Kpa (15 psi) with pressure tester and
check water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(5) Install camshaft sprockets and target ring.
Torque bolts to 101 N´m (75 ft. lbs.) while holding
camshaft sprocket with Special tool C-4687 and
adaptor C-4687-1.
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(7) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- INSTALLATION).
Fig. 15 Water Pump - 2.4L
1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 16 Water Pump Body
1 - IMPELLER
2 - WATER PUMP BODY
3 - O-RING LOCATING GROOVE
7s - 28 ENGINEKJ
WATER PUMP - 2.4L (Continued)

(8) Install the accessory drive mounting bracket
(Fig. 17).(9) Install the power steering pump.
(10) Install the generator.
(11) Install the A/C compressor.
(12) Install the belt tensioner.
(13) Install the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(14) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(15) Lower vehicle and connect battery cable.
Fig. 17 ACCESSORY DRIVE BRACKET
1- UPPER TIMING BELT COVER
2- LOWER TIMING BELT COVER
3- BELT TENSIONER
4- ACCESSORY DRIVE BRACKET
KJENGINE7s-29
WATER PUMP - 2.4L (Continued)

INSTALLATION
2.4L
The Camshaft Position Sensor (CMP) on the 2.4L
4±cylinder engine is bolted to the right-front side of
the cylinder head.Sensor position (depth) is
adjustable.
(1) Remove plastic, upper timing belt cover (timing
gear cover) (Fig. 11) by removing 3 bolts. Before
attempting to remove cover, remove electrical connec-
tor from Engine Coolant Temperature (ECT) sensor
(Fig. 11). This will prevent damage to sensor.
(2) Rotate (bump over) engine until camshaft tim-
ing gear and target wheel (tonewheel) are positioned
and aligned to face of sensor as shown in (Fig. 12).If
not positioned as shown in (Fig. 12), damage to
both sensor and target wheel will occur when
attempting to start engine. Face of sensor
MUST be behind target wheel while adjusting.
(3) Position sensor to cylinder head and install 2
sensor mounting bolts finger tight.
(4)SENSOR AIR GAP: .030ºSet air gap between
rear of target wheel and face of sensor to .030º. This
can best be accomplished using an L-shaped, wire-
type spark plug gapping gauge (Fig. 13). A piece of
.030º brass shim stock may also be used.
(5) Gently push sensor forward until it contacts
gapping gauge.Do not push hard on sensor.
Tighten 2 sensor mounting bolts. Refer to torque
specifications.CAUTION: After tightening sensor mounting bolts,
recheck air gap and adjust as necessary. Retorque
bolts.
(6) Install upper timing belt cover and 3 bolts.
(7) Connect electrical connector to ECT sensor.
(8) Connect electrical connector to CMP sensor.
Fig. 11 UPPER TIMING BELT COVER/BOLTS-2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
3 - MOUNTING BOLTS (3)
Fig. 12 CMP FACE AT TARGET WHEEL-2.4L
1 - CAMSHAFT DRIVE GEAR
2 - TARGETWHEEL (TONEWHEEL)
3 - FACE OF CMP SENSOR
4 - CUTOUT (NOTCH)
Fig. 13 CMP ADJUSTMENT - 2.4L
1 - FACE OF SENSOR
2 - WIRE GAPPING TOOL
8I - 8 IGNITION CONTROLKJ
CAMSHAFT POSITION SENSOR (Continued)

subjected to a high torque load, deposits partially liq-
uefy and bridge the gap between electrodes (Fig. 23).
This short circuits the electrodes. Spark plugs with
electrode gap bridging can be cleaned using standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel-
low (Fig. 24). They may appear to be harmful, but
this is a normal condition caused by chemical addi-
tives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease
spark plug misfire tendencies. Notice that accumula-
tion on the ground electrode and shell area may be
heavy, but the deposits are easily removed. Spark
plugs with scavenger deposits can be considered nor-
mal in condition and can be cleaned using standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions,
severe detonation can also separate the insulator
from the center electrode (Fig. 25). Spark plugs with
this condition must be replaced.
PREIGNITION DAMAGE
Preignition damage is usually caused by excessive
combustion chamber temperature. The center elec-
trode dissolves first and the ground electrode dis-
solves somewhat latter (Fig. 26). Insulators appear
relatively deposit free. Determine if the spark plug
has the correct heat range rating for the engine.
Determine if ignition timing is over advanced or if
other operating conditions are causing engine over-heating. (The heat range rating refers to the operat-
ing temperature of a particular type spark plug.
Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thick-
ness and length of the center electrodes porcelain
insulator.)
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
27). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 2000 miles of opera-
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
Fig. 23 Electrode Gap Bridging
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
Fig. 24 Scavenger Deposits
1 - GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
2 - CENTER ELECTRODE
Fig. 25 Chipped Electrode Insulator
1 - GROUND ELECTRODE
2 - CENTER ELECTRODE
3 - CHIPPED INSULATOR
8I - 14 IGNITION CONTROLKJ
SPARK PLUG (Continued)

ENGINE BLOCK
DESCRIPTION.........................39
STANDARD PROCEDURE - CYLINDER BORE
HONING............................39
CLEANING............................39
INSPECTION..........................40
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING - FITTING...............40
CRANKSHAFT
DESCRIPTION.........................42
REMOVAL.............................43
INSPECTION..........................43
INSTALLATION.........................43
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING - FITTING...............45
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................46
INSTALLATION.........................47
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................48
INSTALLATION.........................48
FLEX PLATE
REMOVAL.............................49
INSTALLATION.........................49
PISTON & CONNECTING ROD
DESCRIPTION.........................49
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING . . . 49
STANDARD PROCEDURE - PISTON
FITTING.............................50
REMOVAL.............................50
CLEANING............................51
INSPECTION..........................51
INSTALLATION.........................51
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................54
INSTALLATION.........................55
STRUCTURAL COVER
DESCRIPTION.........................55
OPERATION...........................55
REMOVAL.............................55
INSTALLATION.........................55
FRONT MOUNT
REMOVAL.............................56
INSTALLATION.........................57
REAR MOUNT
REMOVAL.............................57
INSTALLATION.........................57
LUBRICATION
DESCRIPTION.........................57
OPERATION...........................58DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK...............................60
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE..........................60
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS.........................61
OIL
STANDARD PROCEDURE - ENGINE OIL.....61
OIL FILTER
REMOVAL.............................63
INSTALLATION.........................63
OIL PAN
DESCRIPTION.........................63
REMOVAL.............................63
CLEANING............................63
INSPECTION..........................63
INSTALLATION.........................64
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................65
OPERATION...........................65
REMOVAL.............................65
INSTALLATION.........................65
OIL PUMP
REMOVAL.............................65
DISASSEMBLY.........................65
INSPECTION..........................66
ASSEMBLY............................67
INSTALLATION.........................67
INTAKE MANIFOLD
DESCRIPTION.........................68
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................68
REMOVAL.............................68
INSTALLATION.........................69
EXHAUST MANIFOLD
DESCRIPTION.........................69
REMOVAL.............................69
INSTALLATION.........................70
VALVE TIMING
DESCRIPTION.........................71
OPERATION...........................71
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR.......71
SERVICE PROCEDURES...............72
BALANCE SHAFT
REMOVAL.............................74
INSTALLATION.........................74
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................74
INSTALLATION.........................76
IDLER SHAFT
REMOVAL.............................77
INSTALLATION.........................77
TIMING BELT/CHAIN AND SPROCKET(S
REMOVAL.............................77
INSPECTION..........................79
INSTALLATION.........................80
9 - 2 ENGINE - 3.7LKJ

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal
damaged.5. Re-seal timing cover.
6. Scratched or damaged vibration
damper hub.6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
6. Thin or diluted oil. 6. Change oil and filter.
7. Excessive bearing clearance. 7. Replace as necessary.
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pump suction tube loose,
damaged or clogged.9. Replace as necessary.
KJENGINE - 3.7L 9 - 7
ENGINE - 3.7L (Continued)

(35) Install the mechanical cooling fan.
(36) Install the fan shroud with the electric fan
assembly.
(37) Install the radiator core support bracket.
(38) Install the air cleaner assembly.
(39) Refill the engine cooling system.
(40) Install the hood.
(41) Check and fill engine oil.
(42) Connect the battery negative cable.
(43) Start the engine and check for leaks.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 Ð
Bearing Cap Bolts 11 Ð 100
Timing Chain CoverÐBolts 54 40 Ð
Connecting Rod CapÐBolts 27 20 Ð
PLUS 90É TURN
Bed PlateÐBolts Refer to Procedure
Crankshaft DamperÐBolt 175 130 Ð
Cylinder HeadÐBolts
M11 Bolts Refer ToProcedure
M8 Bolts - - -
Cylinder Head CoverÐBolts 12 Ð 105
Exhaust ManifoldÐBolts 25 18 Ð
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
FlexplateÐBolts 60 45 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick Tube to Engine
BlockÐBolt 15 Ð 130
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner
ArmÐSpecial
Pin Bolt 17 Ð 150
Hydraulic TensionerÐBolts 28 Ð 250
Timing Chain Primary
TensionerÐBolts28 Ð 250
Timing Drive Idler SprocketÐ
Bolt34 25 Ð
Thermostat HousingÐBolts 12 Ð 105
Water PumpÐBolts 54 40 Ð
3.7L ENGINE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Engine Type 90É SOHC V-6 12-Valve
Displacement 3.7 Liters / 3700 cc
( Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 90.8 mm (3.40 in.)
Compression Ratio 9.1:1
Horsepower 210 BHP @ 5200 RPM
Torque 225 LB-FT @ 4200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-6-5-4-3-2
CYLINDER BLOCK
Cylinder Block Cast Iron
Bore Diameter 93.0   .0075 mm
(3.6619   0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
9 - 12 ENGINE - 3.7LKJ
ENGINE - 3.7L (Continued)

Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the left side
exhaust manifold.
(4) Drain the engine coolant. Refer to COOLING
SYSTEM.
(5) Lower the vehicle.
(6) Remove the intake manifold. Refer to proce-
dure in this section.
(7) Remove the cylinder head cover. Refer to proce-
dure in this section.
(8) Remove the fan shroud and fan blade assembly.
Refer to COOLING SYSTEM.
(9) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(10) Remove the power steering pump and set
aside.
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark (Fig. 4).
(12) Verify the V6 mark on the camshaft sprocket
is at the 12 o'clock position (Fig. 5). Rotate the crank-
shaft one turn if necessary.
(13) Remove the crankshaft damper. Refer to Pro-
cedure.
(14) Remove the timing chain cover. Refer to pro-
cedure.
Fig. 4 Engine Top Dead Center
1 - TIMING CHAIN COVER
2 - CRANKSHAFT TIMING MARKS
9 - 20 ENGINE - 3.7LKJ
CYLINDER HEAD - LEFT (Continued)