2002 JEEP LIBERTY Engine removal

Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can alsoweaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DIAGNOSIS CHART
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction. Con-
ditions, causes and corrective action are outlined in
the indicated columns.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.1. Leak at rear main engine seal or
transmission input shaft seal.1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.1. Release bearing sticking or
binding and does not return to the
normal running position.1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.1. Rough handling. Impact bent
cover, spring, or disc.1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.2. Tighten clutch cover using proper
procedure.
KJCLUTCH 6 - 3
CLUTCH (Continued)

CLUTCH DISC
REMOVAL
(1) Remove transmission.
(2) Mark position of pressure plate on flywheel
with paint or a scriber for assembly reference, if
clutch is not being replaced.
(3) Loosen pressure plate bolts evenly and in rota-
tion to relieve spring tension and avoid warping the
plate.
(4) Remove pressure plate bolts and pressure plate
and disc.
INSTALLATION
(1) Lightly scuff sand flywheel face with 180 grit
emery cloth, then clean with a wax and grease
remover.
(2) Lubricate pilot bearing with Mopar high tem-
perature bearing grease or equivalent.
(3) Check runout and operation ofnewclutch disc.
NOTE: Disc must slide freely on transmission input
shaft splines.
(4) With the disc on the input shaft, check face
runout with dial indicator. Check runout at disc hub
6 mm (1/4 in.) from outer edge of facing. Obtain
another clutch disc if runout exceed 0.5 mm (0.020
in.).
(5) Position clutch disc on flywheel with side
marked flywheel against the flywheel.
NOTE: If not marked, the flat side of disc hub goes
towards the flywheel on the 3.7L engine and
towards the transmission on 2.4L engine.
(6) Insert clutch alignment tool through the clutch
disc and into the pilot bearing (Fig. 1).
(7) Position clutch pressure plate over disc and on
the flywheel (Fig. 1).
(8) Install pressure plate bolts finger tight.
CAUTION: Use only the factory bolts to mount the
pressure plate. The bolts must be the correct size.
If bolts are too short, there isn't enough thread
engagement, if too long bolts interfere with the Dual
Mass Flywheel.
(9) Tighten pressure plate bolts evenly and in rota-
tion a few threads at a time.
CAUTION: The bolts must be tightened evenly and
to specified torque to avoid distorting the pressure
plate.(10) Tighten pressure plate bolts to 31 N´m (23 ft.
lbs.) on 2.4L engines and 50 N´m (37ft. lbs.) on 3.7L
engines.
(11) Apply light coat of Mopar high temperature
bearing grease or equivalent to clutch disc hub and
splines of transmission input shaft.
CAUTION: Do not over lubricate shaft splines. This
will result in grease contamination of disc.
(12) Install transmission.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission.
(2) Disconnect release bearing from release lever
and remove the bearing (Fig. 2).
(3) Inspect bearing slide surface of transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(4) Inspect release fork and fork pivot. Be sure
pivot is secure and in good condition. Be sure fork is
not distorted or worn. Replace release fork retainer
spring if bent or damaged.
INSTALLATION
(1) Lubricate crankshaft pilot bearing with Mopar
high temperature bearing grease or equivalent. Apply
grease to end of long shank, small diameter flat
blade screwdriver. Then insert tool through clutch
disc hub to reach bearing.
Fig. 1 ALIGNING CLUTCH DISC
1 - FLYWHEEL
2 - PRESSURE PLATE
3 - CLUTCH DISC ALIGNMENT TOOL
6 - 6 CLUTCHKJ

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)

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
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.1. (a) Radiator cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
Replace if necessary
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose - 4.0L. 1. Replace fan blade assembly.
(Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL)
2. Fan blades striking a surrounding
object.2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or air
conditioning condenser.3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing - 4.0L4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN -
REMOVAL).
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION1. Has a Diagnostic trouble Code
(DTC) been set?1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Obstructions in heater hose/
fittings3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - DIAGNOSIS AND
TESTING). If a slipping belt is
detected, (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- REMOVAL). If heater core
obstruction is detected, (Refer to 7 -
COOLING - STANDARD
PROCEDURE) for cooling system
reverse flushing.
7 - 10 COOLINGKJ
COOLING (Continued)

(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator
is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
ment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE
Drain the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). Remove the thermostat
housing and thermostat. Install the thermostat hous-
ing. Disconnect the radiator upper hose from the
radiator and attach the flushing gun to the hose. Dis-
connect the radiator lower hose from the water
pump. Attach a lead away hose to the water pump
inlet fitting.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
water. When the engine is filled, apply air in short
blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo-
stat housing (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT - REMOVAL).
Install the thermostat and housing with a replace-
ment gasket (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT -INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
BracketÐBolt
2.4L - Ð -
4.7L 41 30 Ð
Automatic Belt Tensioner
PulleyÐ
Bolt
(3.7L) 61 45 Ð
Block HeaterÐBolt
2.4L - Ð -
3.7L 2 Ð 17
Condenser to Radiator Bolts 8 70
Coolant Overflow Bottle to
Plenum mounting bolts - 2.4L
only8.5 75
Coolant Pressure Bottle to
Plenum mounting bolts -3.7L
only8.5 75
Electric Fan to Fan Shroud
bolts5.5 50
Fan Blade Assy. to Viscous
Drive
Bolts 3.7L 23 Ð 210
Fan Shroud to Radiator
Mounting Bolts8Ð70
Radiator Upper Isolator to
Crossmember - Bolts 9.5 Ð 85
Thermostat HousingÐBolts
2.4L - - Ð
4.7L 13 Ð 115
Water PumpÐBolts
2.4L Ð Ð Ð
4.7L 54 40 Ð
KJCOOLING 7 - 13
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
DIAGNOSIS AND TESTING - SERPENTINE
DRIVE BELT.........................15
BELT TENSIONERS
REMOVAL - 3.7L ENGINE.................17INSTALLATION - 3.7L ENGINE.............17
DRIVE BELTS - 3.7L
REMOVAL - 3.7L ENGINE.................17
INSTALLATION - 3.7L ENGINE.............18
ACCESSORY DRIVE
DIAGNOSIS AND TESTING - SERPENTINE
DRIVE BELT
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not a
reason to replace belt. However, cracks running along
a rib (not across) arenotnormal. Any belt with
cracks running along a rib must be replaced (Fig. 1).
Also replace belt if it has excessive wear, frayed cords
or severe glazing.
Refer to SERPENTINE DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
Fig. 1 Serpentine Accessory Drive Belt Wear
Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
KJACCESSORY DRIVE 7 - 15

CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
2. Incorrect belt. 2. Replace belt.
3. Tensile member damaged during
belt installation.3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
BELT TENSIONERS
REMOVAL - 3.7L ENGINE
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from engine front
cover (Fig. 2).WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION - 3.7L ENGINE
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
N´m (30 ft. lbs.).
(3) Install drive belt (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
(4) Check belt indexing marks (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
DRIVE BELTS - 3.7L
REMOVAL - 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.
Fig. 2 Automatic Belt Tensioner
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N´m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
KJACCESSORY DRIVE 7 - 17
ACCESSORY DRIVE (Continued)