2002 JEEP LIBERTY belt

CRANKSHAFT
DESCRIPTION.........................32
OPERATION...........................33
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................33
REMOVAL.............................33
INSPECTION..........................34
INSTALLATION.........................34
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING.............................35
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................37
INSTALLATION.........................37
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................38
INSTALLATION.........................39
PISTON & CONNECTING ROD
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................40
INSTALLATION.........................41
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................42
VIBRATION DAMPER
REMOVAL.............................43
INSTALLATION.........................43
STRUCTURAL COLLAR
REMOVAL.............................44
INSTALLATION.........................44
ENGINE MOUNTING
DESCRIPTION.........................44
FRONT MOUNT
REMOVAL.............................44
INSTALLATION.........................44
REAR MOUNT
REMOVAL.............................45
INSTALLATION.........................45
LUBRICATION
DESCRIPTION.........................46
OPERATION...........................46
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE CHECKING.................46
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............47
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................47
OIL FILTER
DESCRIPTION.........................47
REMOVAL.............................47
INSTALLATION.........................47
OIL PAN
REMOVAL.............................48INSTALLATION.........................48
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................48
OPERATION...........................48
OIL PUMP
REMOVAL.............................49
DISASSEMBLY.........................49
CLEANING............................49
INSPECTION..........................50
ASSEMBLY............................50
INSTALLATION.........................50
INTAKE MANIFOLD
DESCRIPTION.........................51
OPERATION...........................51
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................51
REMOVAL.............................52
INSPECTION..........................52
INSTALLATION.........................52
EXHAUST MANIFOLD
DESCRIPTION.........................53
OPERATION...........................53
REMOVAL.............................53
CLEANING............................53
INSPECTION..........................53
INSTALLATION.........................53
TIMING BELT COVER(S)
REMOVAL.............................53
INSTALLATION.........................53
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............55
REMOVAL - CRANKSHAFT SPROCKET....55
CLEANING............................55
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 56
INSTALLATION - TIMING BELT...........56
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................59
INSTALLATION.........................59
BALANCE SHAFT
DESCRIPTION.........................59
OPERATION...........................59
REMOVAL.............................60
INSTALLATION
BALANCE SHAFT TIMING...............61
BALANCE SHAFT CARRIER
REMOVAL.............................64
INSTALLATION.........................64
BALANCE SHAFT CHAIN
REMOVAL.............................64
INSTALLATION.........................64
9s - 2 ENGINEKJ

crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - ENGINE
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Lash Adjuster (Tappet) Noise Diagnosis
²Engine Oil Leak Inspection
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
KJENGINE9s-5
ENGINE - 2.4L (Continued)

NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) (Refer to 9
- ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
REMOVAL - ENGINE ASSEMBLY
(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 drive belt.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(7) Remove A/C compressor and secure away from
engine with lines attached.
(8) 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.
(9) Remove power steering pump with lines
attached and secure away from engine.
(10) Drain cooling system.
(11) Remove coolant bottle.
(12) Disconnect the heater hoses from the engine.
(13) Disconnect heater hoses from heater core and
remove hose assembly.
(14) Disconnect throttle and speed control cables.
(15) Remove upper radiator hose from engine.
(16) Remove lower radiator hose from engine.
(17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) 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
(19) Remove coil over plugs.
(20) Release fuel rail pressure.(21) Remove fuel rail and secure away from
engine.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors.
(26) Secure the left and right engine wiring har-
nesses away from engine.
(27) Raise vehicle.
(28) Disconnect oxygen sensor wiring.
(29) Disconnect crankshaft postion sensor.
(30) Disconnect the engine block heater power
cable, if equipped.
(31) Disconnect the front propshaft at the front
differential and secure out of way.
(32) Remove the starter.
(33) Remove the ground straps from the engine
(34) Disconnect the exhaust pipes at the manifold.
(35) Remove the structural cover, if equipped.
(36) Remove torque convertor bolts, and mark
location for reassembly.
(37) Remove transmission bellhousing to engine
bolts.
(38) Loosen left and right engine mount thru bolts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(39) Lower the vehicle.
(40) Support the transmission with a suitable jack.
(41) Connect a suitable engine hoist to the engine.
CAUTION: The 2.4L engine with manual transmis-
sions, can be removed without removing the man-
ual transmission. Use caution when attempting this
procedure as the clearance is tight.
(42) Remove engine from vehicle.
INSTALLATION - ENGINE ASSEMBLY
(1) Position the engine in the vehicle.
CAUTION: Use caution when installing 2.4L engine
into vehicle equipped with manual transmission, as
clearance is tight.
(2) Install both left and right side engine mounts
into the frame mounts.
(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.
9s - 12 ENGINEKJ
ENGINE - 2.4L (Continued)

(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.
(12) Install the exhaust pipe.
(13) Connect the oxygen sensors.
(14) Lower vehicle.
(15) Connect the knock sensors.
(16) Connect the engine to body ground straps.
(17) Install the power brake booster vacuum hose.
(18) Install the breather hoses.
(19) Install the PCV hose.
(20) Install the fuel rail.
(21) Install the coil over plugs.
(22) Reconnect 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
(23) Connect lower radiator hose.
(24) Connect upper radiator hose.
(25) Connect throttle and speed control cables.
(26) Install the heater hose assembly.
(27) Install coolant recovery bottle.
(28) Install the power steering pump.
(29) Install the generator.
(30) Install the A/C compressor.
(31) Install the drive belt.
(32) Install the fan shroud with the electric fan
assembly.
(33) Install the radiator core support bracket.
(34) Install the air cleaner assembly.
(35) Refill the engine cooling system.
(36) Install the hood.
(37) Check and fill engine oil.
(38) Connect the battery negative cable.
(39) Start the engine and check for leaks.SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type In-Line OHV, DOHC
Number of Cylinders 4
Displacement 2.4 Liters
(148 cu. in.)
Bore 87.5 mm
(3.445 in.)
Stroke 101.0 mm
(3.976 in.)
Compression Ratio 9.4:1
Firing Order 1-3-4-2
Compression Pressure 690 kPa (Minimum)
(100 psi Minimum)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter 87.4924±87.5076 mm
(3.4446±3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons
Piston Diameter 87.463±87.481 mm
(3.4434±3.4441 in.)
Clearance @ 14 mm
(9/16 in.) from bottom of
skirt0.024±0.057 mm
(0.0009±0.0022 in.)
Weight 346±356 grams
(12.20±12.56 oz.)
Land Clearance
(Diametrical)0.614±0.664 mm
(0.024±0.026 in.)
Piston Length 66.25 mm
(2.608 in.)
Piston Ring Groove
Depth No. 14.640±4.784 mm
(0.182±0.188 in.)
Piston Ring Groove
Depth No. 24.575±4.719 mm
(0.180±0.185 in.)
KJENGINE9s-13
ENGINE - 2.4L (Continued)

DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 20 Ð
Oil Pump Relief
ValveÐCap41 30
Spark Plugs 28 Ð
Timing Belt Covers
- Front Covers to Rear
CoverÐBolts12 Ð 105
- Rear CoverÐBolts 12 Ð 105
Timing Belt Tensioner
AssemblyÐBolts61 45 Ð
SPECIAL TOOLS
2.4L ENGINE
Puller 1026
Crankshaft Damper Removal Insert 6827-A
Camshaft Sprocket Holder 6847
Camshaft Seal Remover C-4679-A
Camshaft Seal Installer MD-998306
Crankshaft Damper Installer 6792
Valve Spring Compressor 8215
Adaptor 8436
KJENGINE9s-17
ENGINE - 2.4L (Continued)

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 - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove intake manifold.
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump and set aside.
Do not disconnect lines.
(11) Remove accessory drive bracket
(12) Remove ignition coil and wires from engine.
(13) Disconnect cam sensor and fuel injector wir-
ing connectors.
(14) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(15) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(16) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(17) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(18) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL).
(19) Remove cylinder head bolts in REVERSE
sequence of tightening.
(20) Remove cylinder head from engine block.
(21) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
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.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
9s - 20 ENGINEKJ
CYLINDER HEAD (Continued)

²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install accessary drive bracket.
(13) Install power steering pump to cylinder head.
(14) Raise vehicle and install the exhaust pipe to
the manifold.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install heater tube support bracket to cylinder
head.
(17) Install intake manifold.
(18) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(19) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(20) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 12).
(3) Remove camshaft sprockets.
(4) Remove exhaust camshaft target ring.
(5) Remove exhaust camshaft sensor.
CAUTION: Inspect sensor and target ring for exces-
sive wear. Clean sensor face and install new spacer
pad.
(6) Remove rear timing belt cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(7) Remove camshaft seal using Special Tool
C-4679-A (Fig. 13).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
NOTE: Clean and inspect sensor and target ring for
excessive wear. Clean sensor face and always
install a new spacer pad.
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
14).
Fig. 10 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 11 Cylinder Head Tightening Sequence
9s - 22 ENGINEKJ
CYLINDER HEAD (Continued)

(3) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
NOTE: Target ring tab should provide posative
snap-on fit on the camshaft.
(4) Install exhaust camshaft target ring with the
wordFRONTfacing forward.
(5) Install exhaust camshaft sensor.
(6) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.).
(7) Install timing belt and front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAINAND SPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
CAMSHAFT(S)
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 15).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the exhaust camshaft on the front of the cylinder
head. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
STANDARD PROCEDURE - CAMSHAFT
END-PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTcam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 16).
(4) Move camshaft as far forward as it will go.
(5) Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
(6) If end play is excessive, check cylinder head
and camshaft for wear; replace as necessary.
Fig. 12 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 13 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
Fig. 14 Camshaft Seal - Installation
1 - SPECIAL TOOL MD 998306
KJENGINE9s-23
CAMSHAFT OIL SEAL(S) (Continued)