2002 JEEP LIBERTY Front light

(11) Bleed fuel system. Refer to FUEL SYSTEM.
(12) Remove fuel rail.
(13) Remove throttle body assembly and mounting
bracket.
(14) Drain cooling system below coolant tempera-
ture level. Refer to COOLING SYSTEM.
(15) Remove the heater hoses from the engine
front cover and the heater core.
(16) Unclip and remove heater hoses and tubes
from intake manifold.
(17) Remove coolant temperature sensor. Refer to
FUEL SYSTEM.
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence.
(19) Remove intake manifold.
INSTALLATION
(1) Install intake manifold gaskets.
(2) Install intake manifold.
(3) Install intake manifold retaining bolts and
tighten in sequence shown in to 12 N´m (105 in. lbs.).
(4) Install left and right radio suppressor straps.
(5) Install throttle body assembly.
(6) Install throttle cable bracket.
(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail.
(9) Install ignition coil towers.
(10) Position and install heater hoses and tubes
onto intake manifold.
(11) Install the heater hoses to the heater core and
engine front cover.
(12) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(13) Install top oil dipstick tube retaining bolt and
ground strap.
(14) Connect generator electrical connections.
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Fill cooling system.
(17) Install resonator assembly and air inlet hose.
(18) Connect negative cable to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 87) are log style with
a patented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high sili-
con molybdenum cast iron. A perforated core graphite
exhaust manifold gasket is used to improve sealing
to the cylinder head. The exhaust manifolds are cov-
ered by a three layer laminated heat shield for ther-
mal protection and noise reduction. The heat shields
(Fig. 88) are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle.
(5) Remove the exhaust heat shield (Fig. 89).
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold and gasket from the cylinder
head.
Fig. 87 EXHAUST MANIFOLDS
1 - LEFT SIDE EXHAUST MANIFOLD
2 - RIGHT SIDE EXHAUST MANIFOLD
KJENGINE - 3.7L 9 - 69
INTAKE MANIFOLD (Continued)

INSTALLATION
(1) Using a vise, lightly compress the secondary
chain tensioner piston until the piston step is flush
with the tensioner body. Using a pin or suitable tool,
release ratchet pawl by pulling pawl back against
spring force through access hole on side of tensioner.
While continuing to hold pawl back, Push ratchet
device to approximately 2 mm from the tensioner
body. Install Special Tool 8514 lock pin into hole on
front of tensioner (Fig. 107). Slowly open vise to
transfer piston spring force to lock pin.
(2) Position primary chain tensioner over oil pump
and insert bolts into lower two holes on tensioner
bracket. Tighten bolts to 28 N´m (250 in. lbs.).
(3) Install right side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 28
N´m (250 in. lbs.).
CAUTION: The silver bolts retain the guides to the
cylinder heads and the black bolts retain the guides
to the engine block.
(4) Install the left side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
(5) Install left side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 28
N´m (250 in. lbs.).(6) Install the right side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
(7) Install both secondary chains onto the idler
sprocket. Align two plated links on the secondary
chains to be visible through the two lower openings
on the idler sprocket (4 o'clock and 8 o'clock). Once
the secondary timing chains are installed, position
special tool 8429 to hold chains in place for installa-
tion.
(8) Align primary chain double plated links with
the timing mark at 12 o'clock on the idler sprocket.
Align the primary chain single plated link with the
timing mark at 6 o'clock on the crankshaft sprocket.
(9) Lubricate idler shaft and bushings with clean
engine oil.
NOTE: The idler sprocket must be timed to the
counterbalance shaft drive gear before the idler
sprocket is fully seated.
(10) Install all chains, crankshaft sprocket, and
idler sprocket as an assembly (Fig. 108). After guid-
ing both secondary chains through the block and cyl-
inder head openings, affix chains with a elastic strap
or the equivalent, This will maintain tension on
chains to aid in installation. Align the timing mark
on the idler sprocket to the timing mark on the coun-
terbalance shaft drive gear, then seat idler sprocket
fully (Fig. 109). Before installing idler sprocket bolt,
lubricate washer with oil, and tighten idler sprocket
assembly retaining bolt to 34 N´m (25 ft. lbs.).
Fig. 107 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 108 Installing Idler Gear, Primary and
Secondary Timing Chains
1 - SPECIAL TOOL 8429
2 - PRIMARY CHAIN IDLER SPROCKET
3 - CRANKSHAFT SPROCKET
9 - 80 ENGINE - 3.7LKJ
TIMING BELT/CHAIN AND SPROCKET(S (Continued)

TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Raise vehicle on hoist.
(3) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELT TENSION-
ERS - REMOVAL)
(4) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(5) Remove air conditioner/generator belt tensioner
and pulley assembly. (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL)
(6) Remove timing belt lower front cover bolts and
remove cover. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - REMOVAL)
(7) Lower vehicle.
(8) Remove bolts attaching timing belt upper front
cover and remove cover. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL)
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(9) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 95).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(10) Install 6 mm Allen wrench into belt tensioner.
Before rotating the tensioner, insert the long end of a
1/8º or 3 mm Allen wrench into the pin hole on the
front of the tensioner (Fig. 96). While rotating the
tensioner counterclockwise, push in lightly on the
1/8º or 3 mm Allen wrench, until it slides into the
locking hole.
(11) Remove timing belt.
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 97).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
Fig. 95 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
KJENGINE9s-55

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA SUPPORT
REMOVAL.............................3
INSTALLATION..........................3
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 3
SPECIFICATIONS - TORQUE.............6
FRONT SKID PLATE
REMOVAL.............................6
INSTALLATION..........................6
ENGINE CRADLE CROSSMEMBER
REMOVAL.............................6
INSTALLATION..........................6TRANSFER CASE SKID PLATE
REMOVAL.............................7
INSTALLATION..........................7
REAR CROSSMEMBER
REMOVAL.............................7
INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................8
INSTALLATION..........................8
REAR TOW HOOK
REMOVAL.............................8
INSTALLATION..........................8
TRAILER HITCH
REMOVAL.............................9
INSTALLATION..........................9
FUEL TANK SKID PLATE
REMOVAL.............................9
INSTALLATION..........................9
FRONT FASCIA
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Raise and support vehicle.
(3) Remove the front wheel opening flare moldings.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL
OPENING FLARE MOLDINGS - REMOVAL)
(4) Remove the four screws through the lower air
dam (Fig. 1).
(5) Disconnect the electrical connectors:
²Fascia to grille opening reinforcement. (Fig. 1)
²Side repeater lights, both sides, if equipped.
(Fig. 2)
(6) Remove the six push pins from the grill sup-
port.
(7) Remove the rivets attaching the air dam to the
wheelhouse splash shield.
(8) Release the support tabs beneath the head-
lamps.
(9) Release the inner support clips from within the
fascia between the lights (Fig. 2).
(10) Remove the fascia.
Fig. 1 FRONT FASCIA
1 - ELECTRICAL CONNECTOR
2 - PUSH PINS
3 - FRONT FASCIA ASSEMBLY
4 - LOWER SCREWS
5 - PLASTIC RIVETS (2)
6 - INNER SUPPORT CLIPS
7 - SUPPORT TABS
KJFRAMES & BUMPERS 13 - 1

INSTALLATION
(1) Install the fascia.
(2) Connect the electrical connectors.
²Side repeater lights, both sides, if equipped.
²Fascia to grille opening reinforcement.
(3) Install the six push pin fasteners into the grill
support.
(4) Install the four screws through the lower air
damn.
(5) Install new rivets attaching the air dam to the
wheelhouse splash shield.
(6) Install the front wheel opening flare moldings.
(Refer to 23 - BODY/EXTERIOR/WHEEL OPENING
FLARE MOLDING - INSTALLATION)
(7) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
REAR FASCIA
REMOVAL
(1) Remove the wheel flares (rear). (Refer to 23 -
BODY/EXTERIOR/REAR WHEEL OPENING
FLARE MOLDINGS - REMOVAL)
(2) Remove the rear lamp units. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
REAR LAMP UNIT - REMOVAL)(3) Remove the four side bolts. (Fig. 3)
(4) Remove the four bottom rivets.
(5) Remove the 3 bolts along the upper edge.
(6) Separate the side plastic retainers and remove
the fascia from the vehicle.
INSTALLATION
NOTE: Fascia must be pushed completely forward
to allow the plastic retainers full engagement in
their respective slots.
(1) Install the fascia and insert the plastic retain-
ers.
(2) Install the three upper bolts.
(3) Install the four side bolts.
(4) Install four bottom rivets.
(5) Install the rear lamp units. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/REAR
LAMP UNIT - INSTALLATION)
(6) Install the rear half wheel opening flares.
(Refer to 23 - BODY/EXTERIOR/WHEEL OPENING
FLARE MOLDING - INSTALLATION)
Fig. 2 FASCIA INNER SUPPORT
1 - INNER SUPPORT CLIP
2 - SIDE REPEATER CONNECTOR (IF EQUIPPED)
3 - FASCIA ASSEMBLY
4 - FOG LAMP
Fig. 3 REAR FASCIA
1 - REAR FASCIA ASSEMBLY
2 - PLASTIC RETAINERS
3 - FASCIA SUPPORT BRACKET
4 - SIDE BOLTS
5 - RIVETS
6 - UPPER BOLTS
13 - 2 FRAMES & BUMPERSKJ
FRONT FASCIA (Continued)

INSTALLATION
2.4L
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.(3) Install sensor into engine block with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
3.7L
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
Fig. 6 CKP SENSOR LOCATION-2.4L
1 - RIGHT FRONT ENGINE MOUNT
2 - CKP SENSOR
3 - MOUNTING BOLT
4 - ELECTRICAL CONNECTOR
Fig. 7 CKP AND O-RING-2.4L
1 - CKP SENSOR
2 - O-RING
Fig. 8 CKP - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
14 - 32 FUEL INJECTIONKJ
CRANKSHAFT POSITION SENSOR (Continued)

NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Raise the front wheels off the ground.
(3) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(4) Check the fluid level add if necessary.
(5) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(6) Stop the engine and check the fluid level and
refill as required.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(7) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
(8) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
REMOVAL
REMOVAL - 3.7L
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the radiator cross member (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).
(3) Remove the engine cooling fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(4) Remove the fan shroud
(5) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove the power steering high pressure hose
at the pump.
(7) Remove the return hose at the pump.
(8) Remove the three bolts securing the pump to
the bracket thru the holes in the pulley. (Fig. 3)
(9) Remove the pump from the vehicle.
REMOVAL - 2.4L
CAUTION: On vehicles equipped with the 2.4L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the serpentine drive belt.
(3) Remove the power steering high pressure hose
at the pump using care not to remove the flow con-
trol valve.
(4) Remove the return hose at the pump.
Fig. 2 FLUID RESERVOIR - 2.4L
Fig. 3 POWER STEERING PUMP - 3.7L
1 - MOUNTING BOLTS
2 - RESERVOIR
3 - STEEL PULLEY
19 - 18 PUMPKJ
PUMP (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
23 - 2 BODYKJ
BODY (Continued)