2002 JEEP LIBERTY battery

CLUTCH PEDAL
REMOVAL
(1) Remove steering column lower cover and knee
blocker for access.
(2) Disconnect clutch pedal position switch wires.
(3) Disengage captured bushing lock tabs attach-
ing clutch master cylinder actuator to pedal pivot.
(4) Remove nuts attaching pedal and bracket to
dash panel and upper cowl support (Fig. 8).
(5) Separate pedal assemble from vehicle.
INSTALLATION
(1) Place clutch pedal and bracket over studs on
dash panel and cowl support.
(2) Install nuts to attach pedal and bracket to
dash panel and upper cowl support. Tighten nuts to
39 N´m (29 ft. lbs.) torque
(3) Engage captured bushing and actuator on
brake pedal pivot.
(4) Connect clutch pedal position switch wires.
CLUTCH SWITCH OVERRIDE
RELAY
DESCRIPTION
The clutch pedal position switch override relay is
located in the Power Distribution Center (PDC).
Refer to PDC cover label for location within PDC.
OPERATION
Refer to Clutch Pedal Position Switch Operation
for information.
REMOVAL
The Clutch Switch Override Relay is located in the
Power Distribution Center (PDC) (Fig. 9). 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 Clutch Switch Override Relay is located in the
Power Distribution Center (PDC). Refer to label on
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
Fig. 8 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
Fig. 9 POWER DISTRIBUTION CENTER (PDC)
1 - BATTERY
2 - PDC
3 - PDC COVER
6 - 10 CLUTCHKJ

CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts its stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 3).INSTALLATION - 3.7L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 3).
(2) Install new belt (Fig. 3). Route the belt around
all pulleys except the idler pulley. Rotate the ten-
sioner arm until it contacts its stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator (Fig. 4). On 3.7L Engines the gap
between the tang and the housing stop ( measure-
ment A ) must not exceed 24 mm (.94 inches).
Fig. 3 Belt Routing - 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 4 Accessory Drive Belt Wear Indicator
1 - AUTOMATIC TENSIONER ASSEMBLY
7 - 18 ACCESSORY DRIVEKJ
DRIVE BELTS - 3.7L (Continued)

INSTALLATION
(1) Apply thread sealant to sensor threads.
(2) Install sensor to engine.
(3) Tighten sensor to 11 N´m (8 ft. lbs.) torque.
(4) Replace any lost engine coolant.
ENGINE COOLANT
THERMOSTAT
DESCRIPTION - 3.7L ENGINE
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator. On all engines the
thermostat is closed below 195ÉF (90ÉC). Above this
temperature, coolant is allowed to flow to the radia-
tor. This provides quick engine warm up and overall
temperature control. On the 3.7L engine the thermo-
stat is designed to block the flow of the coolant
bypass journal by 50% instead of completely blocking
the flow. This design controls coolant temperature
more accurately (Fig. 3).
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: longer engine warmup time, unreli-
able warmup performance, increased exhaust
emissions and crankcase condensation. This conden-
sation can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTING - THERMOSTAT
ON-BOARD DIAGNOSTICS
All models are equipped with On-Board Diagnos-
tics for certain cooling system components.If the pow-
ertrain control module (PCM) detects low engine
coolant temperature, it will record a Diagnostic Trou-
ble Code (DTC). For other DTC numbers, (Refer to 25
- EMISSIONS CONTROL - DESCRIPTION).
The DTC can also be accessed through the DRB
scan tool.
REMOVAL - 3.7L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Remove splash shield.
(5) Remove lower radiator hose clamp and lower
radiator hose at thermostat housing.
(6) Remove thermostat housing mounting bolts,
thermostat housing and thermostat (Fig. 4).
Fig. 3 Thermostat
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
KJENGINE 7 - 21
ENGINE COOLANT TEMPERATURE SENSOR (Continued)

INSTALLATION - 3.7L ENGINE
(1) Clean mating areas of timing chain cover and
thermostat housing.
(2)
Install thermostat (spring side down) into
recessed machined groove on timing chain cover (Fig. 4).
(3) Position thermostat housing on timing chain
cover.
(4) Install two housing-to-timing chain cover bolts.
Tighten bolts to 13 N´m (115 in. lbs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
(5)
Install lower radiator hose on thermostat housing.
(6) Install splash shield.
(7) Lower vehicle.
(8) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(9) Connect negative battery cable to battery.
(10) Start and warm the engine. Check for leaks.
RADIATOR
DESCRIPTION
All vehicles are equipped with a cross flow type
radiator with plastic side tanks (Fig. 5).Plastic tanks, while stronger than brass, are sub-
ject to damage by impact, such as from tools or
wrenches. Handle radiator with care.
Fig. 4 Thermostat and Thermostat Housing
1 - THERMOSTAT HOUSING
2 - THERMOSTAT LOCATION3 - THERMOSTAT AND GASKET
4 - TIMING CHAIN COVER
Fig. 5 Cross Flow Radiator - Typical
1 - RADIATOR
7 - 22 ENGINEKJ
ENGINE COOLANT THERMOSTAT (Continued)

REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 6). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 7). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 8). These are used at the top, bottom
and sides of the radiator and A/C condenser. To
prevent overheating, these seals must be installed
to their original positions.(1) Disconnect the negative battery cable at bat-
tery.
(2) Drain coolant from radiator (Refer to 7 -
COOLING - STANDARD PROCEDURE).
Fig. 6 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 7 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 8 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
KJENGINE 7 - 23
RADIATOR (Continued)

(3) Remove the front grill (Refer to 23 - BODY/EX-
TERIOR/GRILLE - REMOVAL).
(4) Remove the cooling fan from the engine, if
equipped.
(5) Remove the two radiator mounting bolts.
(6) Disconnect both transmission cooler lines from
radiator.
(7) Disconnect the connector for the electric fan.
(8) Disconnect the power steering cooler line from
cooler.
(9) Disconnect the radiator upper and lower hoses.
(10) Disconnect the overflow hose from radiator.
(11) The lower part of radiator is equipped with
two alignment dowel pins (Fig. 9). They are located
on the bottom of radiator tank and fit into rubber
grommets. These rubber grommets are pressed into
the radiator lower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN, HEATING AND AIR CONDI-
TIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
NOTE: The radiator and radiator cooling fan can be
removed as an assembly. It is not necessary toremove the cooling fan before removing or install-
ing the radiator.
(12) Gently lift up and remove radiator from vehi-
cle. Be careful not to scrape the radiator fins against
any other component. Also be careful not to disturb
the air conditioning condenser (if equipped).
CLEANING
Clean radiator fins With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con-
denser of debris.
INSPECTION
The radiator cooling fins should be checked for
damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals are properly
fastened to their original positions. These are used
at the top, bottom and sides of the radiator and A/C
condenser. To prevent overheating, these seals
must be installed to their original positions.
(1) Gently lower the radiator and fan shroud into
the vehicle. Guide the two radiator alignment dowels
into the rubber grommets located in lower radiator
crossmember.
(2) Connect the radiator upper and lower hoses
and hose clamps to radiator.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) Install coolant reserve/overflow tank hose at
radiator.
(4) Connect both transmission cooler lines at the
radiator.
(5) Install both radiator mounting bolts.
(6) Reconnect the electric cooling fan.
(7) Install the grill (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION).
(8) Reinstall the cooling fan to the engine.
(9) Rotate the fan blades (by hand) and check for
interference at fan shroud.
(10) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect battery cable at battery.
(12) Start and warm engine. Check for leaks.
Fig. 9 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
7 - 24 ENGINEKJ
RADIATOR (Continued)

RADIATOR FAN - ELECTRIC
DESCRIPTION
The fan (Fig. 12) is electrically controlled by the
powertrain control module (PCM) through the fan
control relay. This relay is located on the left wheel
house in the engine compartment.
OPERATION
The electric radiator cooling fan is controlled by
the Powertrain Control Module (PCM) through the
radiator cooling fan relay. The PCM regulates fan
operation based on input from the engine coolant
temperature sensor, battery temperature sensor,air
conditioning select switch and vehicle speed.
The fan is not energized during engine cranking
regardless of the electrical input from the tempera-
ture sensors and ,air conditioning switch. However, if
engine operation conditions warrant fan engagement,
the fan will run once engine starts.
On vehicles NOT equipped with AC:The relay
is energized when the coolant temperature is above
80É C (176É F), or battery temperature sensor above ±
12É C (10É F). It will then de-energize when coolant
temperature drops below 82É C (180É F), or batter
temperature sensor below ± 9É C ( 16É F).
Vehicles Equipped with AC:In addition to using
coolant temperature and battery temperature sensorto control cooling fan operation, the cooling fan will
also be engaged when the ,air conditioning system is
activated. The relay is also energized when, air con-
ditioning is selected and coolant temperature is
above 95É C ( 203É F), or , air conditioning is selected
and battery temperature sensor is above 41É C (106É
F). It will then de-energize when , air conditioning is
selected and coolant temperature is below 92É C
(198É F), or , air conditioning is selected and battery
temperature is below 38É C (100É F).
REMOVAL
If the fan blade is bent, warped, cracked or dam-
aged in any way, it must be replacedonlywith a
replacement fan blade.Do not attempt to repair a
damaged fan blade.
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the vicous fan cannot be removed
seperate from the shroud. Both fan and shroud
must be removed together.
(1) Disconnect battery negative cable.
(2) Using special tool 6958 spanner wrench and
8346 adapters, remove the vicous fan from the water
pump (Fig. 13).
(3) Gently lay fan into shroud.
(4) Disconnect the electrical connector for the elec-
tric fan, then disconnect connector from shroud.
Fig. 12 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 13 Viscous Fan and Fan Drive 3.7L
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
7 - 26 ENGINEKJ

(5) Remove the two fan shroud mounting bolts con-
necting the fan shroud to the radiator (Fig. 14).
(6) Remove the shroud and fan from the vehicle.
INSTALLATION
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the vicous fan cannot be installed
seperate from the shroud. Both fan and shroud
must be installed together.
(1) Gently lay vicous fan into shroud.
(2) Install fan shroud assembly into the vehicle.
Tighten fan shroud to radiator bolts to (5.5 N´m (50
in. lbs.).
(3) Using special tool 6958 spanner wrench and
8346 adapters, install the vicous fan on the water
pump.
(4) Connect fan motor wire connector to harness
connector, and attach connector to shroud.
(5) Connect battery negative cable.
(6) Start engine and check fan operation.
RADIATOR - FAN - VISCOUS
DESCRIPTION
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
The thermal viscous fan drive (Fig. 15) is a sili-
cone-fluid-filled coupling used to connect the fan
blades to the water pump shaft. The coupling allows
the fan to be driven in a normal manner. This is
done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
On the 3.7L engine, an electric fan is standard and
the viscous fan is added on for trailer tow packages
only.
OPERATION
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit. This
spring coil reacts to the temperature of the radiator
discharge air. It engages the viscous fan drive for
higher fan speed if the air temperature from the
radiator rises above a certain point. Until additional
engine cooling is necessary,the fan will remain at
a reduced rpm regardless of engine speed. Nor-
mally less than three hundred (300) rpm.
Fig. 14 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 15 Viscous Fan Drive - Typical
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
KJENGINE 7 - 27
RADIATOR FAN - ELECTRIC (Continued)