2002 JEEP LIBERTY steering

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Output Speed Sensor BK Left Side of Transmission 5
Overhead Map/Courtesy Lamp BK Overhead Console N/S
Oxygen Sensor 1/1 Upstream (2.4L) BK Right Side of Engine 12
Oxygen Sensor 1/1 Upstream (3.7L) BK Lower Left Side of Engine 3
Oxygen Sensor 1/2 Downstream
(2.4L)NAT Right Side of Transmission 11, 12
Oxygen Sensor 1/2 Downstream
(3.7L)NAT Left Side of Transmission 5, 7
Oxygen Sensor 2/1 Upstream (3.7L) BK Lower Right Side of Engine 4
Oxygen Sensor 2/2 Downstream
(3.7L)NAT Right Side of Transmission 6
Park Brake Switch BK Center Console 36, 40
Passenger Airbag YL Right Side Instrument Panel N/S
Passenger Seat Belt Switch LG At Passenger Seat N/S
Power Mirror Switch WT In Left Front Door 41
Power Outlet RD Center of Instrument Panel N/S
Power Steering Pressure Switch BK Left Front Side of Engine 3, 15
Power Window Master Switch LG Center Console 36, 40
Powertrain Control Module C1 (2.4L) BK At Powertrain Control Module 13, 14
Powertrain Control Module C1 (3.7L) BK At Powertrain Control Module 8, 9, 10
Powertrain Control Module C2 WT At Powertrain Control Module 8, 9, 10, 13, 14
Powertrain Control Module C3 GY At Powertrain Control Module 31
Radiator Fan Motor BK Right Front Side of Engine
Compartment28
Radiator Fan Relay BK Left Front Side of Engine
Compartment29
Radio C1 GY Rear of Radio N/S
Radio C2 Rear of Radio N/S
Radio C3 Rear of Radio N/S
Radio Choke GY Center of Instrument Panel N/S
Rear Map/Reading Lamp BK Overhead Console N/S
Rear Power Outlet RD Right Rear Quarter Panel 44, 45, 48
Rear Power Window Switch WT Center Console 36, 40
Rear Wheel Speed Sensor BK On Rear Axle N/S
Rear Window Defogger BK At Rear Window 46
Rear Wiper Motor BK In Tailgate 46
Red Brake Warning Indicator Switch
(LHD)GY Left Rear Side of Engine
Compartment31
Red Brake Warning Indicator Switch
(RHD)GY Right Rear Side of Engine
Compartment26
Right Curtain Airbag YL Right Mid B-Pillar 34, 39
Right Cylinder Lock Switch (Except
Base)LG In Right Front Door 41
KJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION8Wa-91-7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Door Lock Switch (Except
Base)BK In Right Front Door 41
Right Fog Lamp BK Right Side of Bumper N/S
Right Front Door Ajar Switch (Base) BK In Right Front Door N/S
Right Front Door Lock Motor/Ajar
Switch (Except Base)BK In Right Front Door 41
Right Front Door Speaker BK In Right Front Door 41
Right Front Impact Sensor BK Right Front Side of Engine
Compartment28
Right Front Park/Turn Signal Lamp BK At Lamp N/S
Right Front Power Window Motor LG In Right Front Door 41
Right Front Wheel Speed Sensor BK Right Rear Lower Side of
Engine Compartment25
Right Headlamp (BUX) Right Front Side of Engine
CompartmentN/S
Right Headlamp (Except BUX) DB Right Front Side of Engine
CompartmentN/S
Right Heated Seat Assembly LG At Right Seat N/S
Right Heated Seat Switch BK At Right Seat N/S
Right Instrument Panel Lamp BK Right Side of Instrument
PanelN/S
Right Instrument Panel Speaker WT Right Side of Instrument
Panel33, 37
Right Leveling Motor (BUX) BK At Right Headlamp N/S
Right Position Lamp (BUX) BK Right Front Corner of Vehicle N/S
Right Power Mirror WT In Right Front Door 41
Right Power Seat Motors BK At Right Seat N/S
Right Power Seat Switch GN At Right Seat N/S
Right Rear Door Ajar Switch (Base) BK In Right Rear Door N/S
Right Rear Door Lock Motor/Ajar
Switch (Except Base)BK In Right Rear Door 42
Right Rear Door Speaker At Speaker 42
Right Rear Power Window Motor LG In Right Rear Door 42
Right Remote Radio Switch BK On Steering Wheel N/S
Right Side Impact Airbag Control
Module (RSIACM)YL Lower Right B-Pillar 34, 39
Right Side Marker Lamp BK Right Front Fender N/S
Right Side Repeater Lamp (BUX) BK Right Front Fender N/S
Right Speed Control Switch WT On Steering Wheel N/S
Right Tail/Stop Lamp BK Right Rear Quarter Panel 45
Right Visor/Vanity Lamp WT On Visor N/S
Sentry Key Immobilizer Module BK Under Left Side of
Instrument PanelN/S
Shifter Assembly WT Center Console 36, 40
8Wa - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONKJ
CONNECTOR/GROUND/SPLICE LOCATION (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)

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)

(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the eight M11 bolts.
(5) Coat the four M8 cylinder head bolts with
MopartLock and Seal Adhesivethen install the
bolts.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tighten the bolts in sequence using the follow-
ing steps and torque values:
²Step 1: Tighten bolts 1±10, 27 N´m (20 ft. lbs.).
²Step 2: Verify that bolts 1±10, all reached 27
N´m (20 ft. lbs.), by repeating step-1 without loosen-
ing the bolts. Tighten bolts 11 thru 14 to 14 N´m (10
ft. lbs.).
²Step 3: Tighten bolts 1±10, 90 degrees (Fig. 11).
²Step 4: Tighten bolts 1±10, 90 degrees, again.
Tighten bolts 11±14, 26 N´m (19 ft. lbs.)
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V6 mark on the gear then using
Special Tool 8428 Camshaft Wrench, position the
gear onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the left side secondary chain guide.(10) Install the cylinder head access plug.
(11) Re-set and Install the left side secondary
chain tensioner.
(12) Remove Special Tool 8429.
(13) Install the timing chain cover.
(14) Install the crankshaft damper. Tighten
damper bolt 175 N´m (130 Ft. Lbs.).
(15) Install the power steering pump.
(16) Install the fan blade assembly and fan
shroud.
(17) Install the cylinder head cover.
(18) Install the intake manifold.
(19) Refill the cooling system
(20) Raise the vehicle.
(21) Install the exhaust pipe onto the left exhaust
manifold.
(22) Lower the vehicle.
(23) Connect the negative cable to the battery.
(24) Start the engine and check for leaks.
CAMSHAFT(S)
DESCRIPTION
The camshafts consist of powdered metal steel
lobes which are sinter-bonded to a steel tube. Four
bearing journals are machined into the camshaft.
Camshaft end play is controlled by two thrust walls
that border the nose piece journal. Engine oil enters
the hollow camshafts at the third journal and lubri-
cates every intake lobe rocker through a drilled pas-
sage in the intake lobe.
Fig. 10 Proper Tool Usage For Surface Preparation
1 - PLASTIC/WOOD SCRAPERFig. 11 CYLINDER HEAD TIGHTENING SEQUENCE
KJENGINE - 3.7L 9 - 23
CYLINDER HEAD - LEFT (Continued)

IDLER SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains and sprockets. Refer to procedure in this sec-
tion.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore.
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil.
(5) Install the timing chains and sprockets. Refer
to procedure in this section.
TIMING BELT/CHAIN AND
SPROCKET(S
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to COOLING SYS-
TEM for procedures.
(3) Remove right and left cylinder head covers.
Refer to CYLINDER HEAD COVER.
(4) Remove radiator fan shroud. Refer to COOL-
ING SYSTEM for procedure.
(5) Rotate engine until timing mark on crankshaft
damper aligns with TDC mark on timing chain cover
(Fig. 103) (#1 cylinder exhaust stroke) and the cam-
shaft sprocket ªV6º marks are at the 12 o'clock posi-
tion (Fig. 102).
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed
retorque nut to 5 N´m (44 in. lbs.).
(6) Remove power steering pump. Refer to STEER-
ING for procedure.
(7) Remove access plug from left and right cylinder
heads for access to chain guide fasteners (Fig. 104).
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper and timing chain
cover. Refer to procedures.
(10) Collapse and pin primary chain tensioner.
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chain tensioners.
(12) Remove camshaft position and crankshaft
position sensors (Fig. 105) and (Fig. 106).
KJENGINE - 3.7L 9 - 77

(20) After installing all chains, it is recommended
that the idler gear end play be checked (Fig. 112).
The end play must be within 0.10±0.25 mm (0.004±
0.010 in.). If not within specification, the idler gear
must be replaced.
(21) Install timing chain cover and crankshaft
damper. Refer to procedures.
(22) Install cylinder head covers. Refer to proce-
dures.
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.(23) Coat the large threaded access plug with
MopartThread Sealant with Teflon, then install
into the right cylinder head and tighten to 81 N´m
(60 ft. lbs.).
(24) Install the oil fill housing.
(25) Install access plug in left cylinder head.
(26) Install power steering pump.
(27) Fill cooling system.
(28) Connect negative cable to battery.
Fig. 111 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKETFig. 112 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
9 - 82 ENGINE - 3.7LKJ
TIMING BELT/CHAIN AND SPROCKET(S (Continued)