2002 JEEP LIBERTY Workshop Manual

DESCRIPTION - COOLING SYSTEM ROUTING
3.7L ENGINE
For cooling system routing refer to (Fig. 1).
DESCRIPTION - HOSE CLAMPS
The cooling system utilizes spring type hose
clamps. If a spring type clamp replacement is neces-
sary, replace with the original Mopartequipment
spring type clamp.
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. 2). 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. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 2).
OPERATION
OPERATION - COOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
Fig. 1 Engine Cooling System 3.7L Engine
1 - LH CYL. HEAD
2 - AIR BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
7 - 2 COOLINGKJ
COOLING (Continued)

The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
OPERATION - HOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrain control module (PCM) has been
programmed to monitor certain cooling system com-
ponents:
²If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) can be set.
²If an open or shorted condition has developed in
the relay circuit controlling the electric radiator fan,
a Diagnostic Trouble Code (DTC) can be set.
If the problem is sensed in a monitored circuit
often enough to indicated an actual problem, a DTC
is stored. The DTC will be stored in the PCM mem-
ory for eventual display to the service technician.
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC's and to obtain cooling system data,
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRB
scan tool to erase a DTC. Refer to the appropriate
Powertrain Diagnostic Procedures service informa-
tion for operation of the DRB scan tool.
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED
²STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
(1) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(2) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump, or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only. Refer to the group text for information.
Fig. 2 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
KJCOOLING 7 - 3
COOLING (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate engine until radiator
upper hose is warm to touch. Aim the commercially
available black light tool at components to be
checked. If leaks are present, black light will cause
additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 3).
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if cause of coolant
loss is not located during the warm engine examina-
tion.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove radiator pressure cap from pres-
sure bottle and check coolant level. Push down on
cap to disengage it from stop tabs. Wipe inside of
filler neck and examine lower inside sealing seat fornicks, cracks, paint, and dirt. Inspect radiator-to-
reserve/overflow tank hose for internal obstructions.
Insert a wire through the hose to be sure it is not
obstructed.
Inspect cams on outside of filler neck. If cams are
damaged, seating of pressure cap valve and tester
seal will be affected.
Attach pressure tester (7700 or an equivalent) to
radiator filler neck (Fig. 4).
Operate tester pump to apply 110 kPa (16 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Holds Steady:If pointer remains steady for two
minutes, serious coolant leaks are not present in sys-
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Internal Leakage Test.
Drops Slowly:Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
Fig. 3 Leak Detection Using Black Light - Typical
1 - TYPICAL BLACK LIGHT TOOL
Fig. 4 Pressure Testing Cooling System - Typical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
7 - 4 COOLINGKJ
COOLING (Continued)

the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 124 KPA (18 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack in engine. Repair
as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
KJCOOLING 7 - 5
COOLING (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?1. Refer to (Refer to 25 -
EMISSIONS CONTROL -
DESCRIPTION) for On-Board
Diagnostics and DTC information.
Replace thermostat if necessary.
2. Is the temperature sending unit
connected?2. Check the temperature sensor
connector. (Refer to 7 - COOLING/
ENGINE/ENGINE COOLANT TEMP
SENSOR - DESCRIPTION). Repair
connector if necessary.
3. Is the temperature gauge
operating OK?3. Check gauge operation. Repair
as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.4. Check coolant level in the coolant
pressure botttle and the radiator.
Inspect system for leaks. Repair
leaks as necessary.
5. Improper operation of internal
heater doors or heater controls.5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING)
6. Electric fan functioning when not
required.6. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to group
8W for electric cooling fan and relay
circuit schematic data.
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair.
2. Is the temperature gauge reading
correctly?2. Check gauge. (Refer to Group 8J
- INSTRUMENT CLUSTER). Repair
as necessary.
3. Is the temperature warning
illuminating unnecessarily?3. Check warning lamp operation.
(Refer to Group 8J - INSTRUMENT
CLUSTER).Repair as necessary.
4. Coolant low in coolant pressure
bottle and radiator?4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
7 - 6 COOLINGKJ
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant not flowing through
system.7. (a) Check condition of pressure
bottle cap and cap seals. (Refer to
7 - COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING).
(b) Check condition of radiator vent
nipple. If neck is damaged, replace
radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check pressure bottle/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to 7 -
COOLING/ENGINE/COOLANT -
DESCRIPTION) for correct
coolant/water mixture ratio.
9. Fan installed backwards on
viscous drive.9. Mount fan on drive correctly.
10. Radiator or A/C condenser fins
are dirty or clogged.10. Remove insects and debris.
(Refer to 7 - COOLING/ENGINE/
RADIATOR - CLEANING).
11. Radiator core is corroded or
plugged.11. Have radiator re-cored or
replaced.
12. Fuel or ignition system
problems.12. Refer to FUEL and /or
IGNITION CONTROL for diagnosis.
13. Dragging brakes. 13. Check and correct as
necessary. (Refer to 5 - BRAKES -
DIAGNOSIS AND TESTING) for
correct procedures.
14. Bug screen or cardboard is
being used, reducing airflow.14. Remove bug screen or
cardboard.
KJCOOLING 7 - 7
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
15. Thermostat partially or
completely shut.15. Check thermostat operation and
replaces necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
DIAGNOSIS AND TESTING).
16. Viscous fan drive not operating
properly.16. Check fan drive operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING).
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING). For
repair, (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
18. Heater core leaking. 18. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
Repair as necessary.
19. Electric fan not functioning. 19. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to Group
8W for electric cooling fan and relay
circuit schematic data.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and
repair if necessary. Refer to Group
8J, Instrument cluster.
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in cooling
system (air will build up in the
cooling system causing the
thermostat to open late).5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
7 - 8 COOLINGKJ
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
DIAGNOSIS AND TESTING).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in pressure
bottle cap is defective.1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.2. Check coolant concentration.
(Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) and
adjust ratio as required.
KJCOOLING 7 - 9
COOLING (Continued)