2002 JEEP LIBERTY Jb power

STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove structural collar attaching bolts.
(3) Remove collar.
INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.
(1) Perform the following steps for installing struc-
tural collar.
²Step 1: Position collar between transmission and
oil pan. Install collar to transmission bolts,hand
start only.
²Step 2: Install collar to oil pan bolts,hand snug
only.
²Step 3: Tighten collar to transmission bolts.
²Step 4: Tighten collar to oil pan bolts.
(2) Lower vehicle.
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of three
mounts; right and a left side support the powertrain,
and rear mount to control powertrain torque. The
mounts are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the front engine mount through bolt
from the insulator.
(3) Remove the engine front mount bolts and
remove the insulator assembly.
(4) Remove the front mounting bracket from
engine, if necessary.
INSTALLATION
(1) Install the insulator mount assembly (Fig.
72)and (Fig. 73).
(2) Tighten the mount to engine bolts.
(3) Loosely install the front engine mount through
bolt to the insulator.
(4) Lower the engine.
(5) Tighten the through bolt.
(6) Lower the vehicle.
Fig. 72 LH ENGINE MOUNT
1 - ENGINE MOUNT
2 - ENGINE MOUNT BOLT (3)
3 - ENGINE MOUNT THROUGH BOLT
Fig. 73 RH ENGINE MOUNT
1 - ENGINE MOUNT BOLT (4)
2 - ENGINE MOUNT THROUGH BOLT
3 - ENGINE MOUNT
9s - 44 ENGINEKJ

(3) Screw oil filter on until the gasket contacts
base. Tighten to 21 N´m (15 ft. lbs.).
OIL PAN
REMOVAL
(1) Remove air cleaner assembly.
(2) Raise vehicle on hoist and drain engine oil.
(3) Loosen the engine mount thru bolts.
(4) Disconnect exhaust pipe at manifold.
(5) Remove structural collar, if equipped.
(6) Remove front axle mounting bolts, and lower
axle as far possible, if equipped.
(7) Using suitable jack, raise engine as needed.
(8) Remove oil pan attaching bolts.
(9) Remove oil pan.
(10) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Install the oil pan gasket to the block.
(2) Apply a 3MM (1/8 inch) bead of MopartEngine
RTV at the oil pump to engine block parting line
(Fig. 80).
(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
(4) Lower engine, and remove jack.
(5) Tighten engine mount thru bolts.
(6) Raise the front axle into position, and reinstall
front axle mounting bolts. If equipped.
(7) Reconnect exhaust pipe to manifold.
(8) Install structural collar, if equipped.
(9) Lower vehicle.(10) Fill engine crankcase with proper oil to cor-
rect level.
(11) Reinstall air cleaner assembly.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, electrical/mechanical engine oil pres-
sure sensor (sending unit) is located in an engine oil
pressure gallery.
OPERATION
The oil pressure sensor uses three circuits. They
are:
²A 5±volt power supply from the Powertrain Con-
trol Module (PCM)
²A sensor ground through the PCM's sensor
return
²A signal to the PCM relating to engine oil pres-
sure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5±volt supply is sent to the sensor from the PCM
to power up the sensor. The sensor returns a voltage
signal back to the PCM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
Fig. 79 2.4 OIL FILTERFig. 80 OIL PAN GASKET INSTALLATION
1 - SEALER LOCATION
9s - 48 ENGINEKJ
OIL FILTER (Continued)

(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect connector from inlet air tempera-
ture sensor.
(3) Disconnect air intake tube at throttle body and
remove upper air cleaner housing.
(4) Disconnect connector from throttle position
sensor (TPS).
(5) Disconnect connector from idle air control (IAC)
motor.
(6) Disconnect connector from MAP sensor.
(7) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold.
(8) Remove vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at intake manifold fittings.
(9) Disconnect throttle, speed control (if equipped),
and transaxle control (if equipped) and cables from
throttle lever and bracket. (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/THROTTLE CONTROL
CABLE - REMOVAL)
(10) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(11) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(12) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(13) Disconnect fuel injector harness.
(14) Remove intake manifold to cylinder head fas-
teners.
(15) Remove the manifold from engine.
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(16) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Install new manifold to cylinder head seals.
(3) Install manifold to head.
(4) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown (Fig. 90).
Repeat procedure until all bolts are at specified
torque.
(5) Install throttle cables in bracket.
(6) Connect throttle, speed control, (if equipped),
cables to throttle lever.
(7) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(8) Connect vacuum lines for purge solenoid and
PCV valve.
(9) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(10) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(11) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(12) Install the air cleaner housing and air intake
tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor.
(14) Connect negative cable to battery.
Fig. 90 LOWER INTAKE MANIFOLD TIGHTENING
SEQUENCE
9s - 52 ENGINEKJ
INTAKE MANIFOLD (Continued)

SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
ENGINE CRADLE CROSSMEMBER INNER RAIL BOLTS 47 35 Ð
ENGINE CRADLE CROSSMEMBER MOUNTING BOLTS 122 90 Ð
ENGINE MOUNT THROUGH BOLTS/NUTS 88 65 Ð
FRONT SKID PLATE BOLTS 61 45 Ð
FRONT TOW HOOK NUTS/BOLT 61 45 Ð
FUEL TANK SKID PLATE 88 65 Ð
REAR CROSSMEMBER BOLTS 47 35 Ð
REAR TOW HOOK BOLTS 88 65 Ð
TRAILER HITCH BOLTS 88 65 Ð
TRANSFER CASE SKID PLATE BOLTS 34 25 Ð
TRANSMISSION MOUNT THROUGH BOLT/NUT 88 65 Ð
FRONT SKID PLATE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the skid plate bolts and remove the
skid plate. (Fig. 7)
INSTALLATION
(1) Install the skid plate.
(2) Install the bolts and tighten to 61 N´m (45 ft.
lbs.).
ENGINE CRADLE
CROSSMEMBER
REMOVAL
(1) Install a suitable engine support tool.
(2) Raise and support the vehicle.
(3) Remove the lower control arms. (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL)
(4) Remove the sway bar. (Refer to 2 - SUSPEN-
SION/FRONT/STABILIZER BAR - REMOVAL)
(5) Remove the front axle, if equipped. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/FRONT AXLE -
REMOVAL)
(6) Remove the power steering rack. (Refer to 19 -
STEERING/GEAR - REMOVAL)
(7) Loosen the engine mount through bolts.
(8) Support the engine cradle with a suitable lift-
ing device.
(9) Using a grease pencil or equivalent, mark the
location of the engine support cradle.
(10) Remove the engine cradle bolts and remove
the engine cradle.
INSTALLATION
(1) Raise and support the vehicle.
(2) Using a suitable lifting device raise the engine
cradle into the vehicle while lining up the engine
mount through bolts.
Fig. 7 SKID PLATE
1 - SKID PLATE
2 - BOLTS (4)
13 - 6 FRAMES & BUMPERSKJ
FRAME (Continued)

(3) Align the engine cradle to the marks made dur-
ing removal and install the mounting and inner rail
bolts.
(4) Tighten the mounting bolts to 122 N´m (90 ft.
lbs.).
(5) Tighten the inner rail bolts to 47 N´m (35 ft.
lbs.).
(6) Tighten the engine mount through bolts to 88
N´m (65 ft. lbs.).
(7) Install the power steering rack. (Refer to 19 -
STEERING/GEAR - INSTALLATION)
(8) Install the front axle, if equipped. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/FRONT AXLE -
INSTALLATION)
(9) Install the stabilizer bar. (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER BAR - INSTALLA-
TION)
(10) Install the lower control arms. (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION)
(11) Lower the vehicle and remove the engine sup-
port tool.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Remove the bolts and remove the skid plate.
(Fig. 8)
INSTALLATION
(1) Install the skid plate.
(2) Install the bolts and tighten to 34 N´m (25 ft.
lbs.).
REAR CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle.
(2) Support the transmission with a suitable lifting
device.
(3) Remove the transmission mount through bolt.
(4) Remove the crossmember bolts and remove the
crossmember. (Fig. 9)
INSTALLATION
(1) Install the crossmember and install the bolts.
(2) Tighten the bolts to 47 N´m (35 ft. lbs.)
(3) Install transmission mount through bolt and
tighten to 88 N´m (65 ft. lbs.).
Fig. 8 SKID PLATE
1 - SKID PLATE
2 - BOLTS
Fig. 9 CROSS MEMBER
1 - CROSSMEMBER
2 - BOLTS
KJFRAMES & BUMPERS 13 - 7
ENGINE CRADLE CROSSMEMBER (Continued)

(8) Pressure should not fall below30 psi for five
minutes.
(9) If pressure falls below 30 psi, it must be deter-
mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.
(10) Again, start engine and bring to normal oper-
ating temperature.
(11) Shut engine off.
(12)Testing for fuel injector or fuel rail leak-
age:Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.
(13)Testing for fuel pump check valve, filter,
regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump, fuel fil-
ter or fuel pressure regulator may be leaking.
Note: A quick loss of pressure usually indicates a
defective check valve in the pressure regulator. A
slow loss of pressure usually indicates a defective
check valve in the bottom of the fuel pump module.
The check valves are not serviced separately. Also,
the electric fuel pump is not serviced separately.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
14 - 4 FUEL DELIVERYKJ
FUEL DELIVERY (Continued)

SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi).
TORQUE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket Mounting Nuts 12 - 105
Crankshaft Position Sensor - 2.4L 28 21 -
Crankshaft Position Sensor - 3.7L 28 21 -
Camshaft Position Sensor - 2.4L 12 - 106
Camshaft Position Sensor - 3.7L 12 - 106
Engine Coolant Temperature Sensor 11 - 96
EVAP Canister-to-Body Bolts 48 35 -
EVAP Canister-to-Canis. Bracket Bolt/Nut 11 - 100
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body Screws 2 - 17
Fuel Filter Mounting Nut at Tank 5.5 - 49
Fuel Pump Module Access Plate Nuts 3 - 26
Fuel Rail Mounting Bolts - 3.7L 11 - 100
Fuel Rail Mounting Bolts - 2.4L 28 - 250
Fuel Tank Heat Sheild Nuts 5.5 - 49
Fuel Tank Mounting Strap Bolts 61 45 -
Fuel Tank Skid Plate and Trailer Hitch 88 65 -
IAC Motor Mounting Screws 7 - 60
Leak Detection Pump Mounting Bracket-to-Fuel
Tank Nuts5.5 - 49
Leak Detection Pump-to-Bracket Nuts 1.2 - 11
Map Sensor Mounting Screws 3 - 25
PCM-to-Mounting Bracket Mounting Screws 4 - 35
Power Steering Pressure Switch 14-22 - 124-195
TPS Mounting Screws 7 - 60
Throttle Body Mounting Bolts 11 - 100
Oxygen Sensors 30 22 -
KJFUEL DELIVERY 14 - 5
FUEL DELIVERY (Continued)

FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
OPERATION
The fuel pump module has 4 different circuits
(wires). Two of these circuits are used for the fuel
gauge sending unit for fuel gauge operation, and for
certain OBD II emission requirements. The other 2
wires are used for electric fuel pump operation.
For Fuel Gauge Operation:A constant current
source of approximately 32 milliamps is supplied to
the resistor track on the fuel gauge sending unit.
This is fed directly from the Powertrain Control Mod-
ule (PCM).NOTE: For diagnostic purposes, this
12V power source can only be verified with the
circuit opened (fuel pump module electrical
connector unplugged). With the connectors
plugged, output voltages will vary from about
0.6 volts at FULL, to about 8.6 volts at EMPTY
(about 8.6 volts at EMPTY for Jeep models, and
about 7.0 volts at EMPTY for Dodge Truck mod-
els).The resistor track is used to vary the voltage
(resistance) depending on fuel tank float level. As
fuel level increases, the float and arm move up,
which decreases voltage. As fuel level decreases, the
float and arm move down, which increases voltage.
The varied voltage signal is returned back to the
PCM through the sensor return circuit.
Both of the electrical circuits between the fuel
gauge sending unit and the PCM are hard-wired (not
multi-plexed). After the voltage signal is sent from
the resistor track, and back to the PCM, the PCM
will interpret the resistance (voltage) data and send
a message across the multi-plex bus circuits to the
instrument panel cluster. Here it is translated into
the appropriate fuel gauge level reading. Refer to
Instrument Panel for additional information.
For OBD II Emission Monitor Requirements:
The PCM will monitor the voltage output sent from
the resistor track on the sending unit to indicate fuel
level. The purpose of this feature is to prevent the
OBD II system from recording/setting false misfire
and fuel system monitor diagnostic trouble codes.
The feature is activated if the fuel level in the tank
is less than approximately 15 percent of its rated
capacity. If equipped with a Leak Detection Pump
(EVAP system monitor), this feature will also be acti-
vated if the fuel level in the tank is more than
approximately 85 percent of its rated capacity.
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT
The fuel level sending unit contains a variable
resistor (track). As the float moves up or down, elec-
trical resistance will change. Refer to Instrument
Panel and Gauges for Fuel Gauge testing. To test the
gauge sending unit only, it must be removed from
vehicle. The unit is a separate part of the lower fuel
pump module section. Refer to Fuel Pump Module
Removal/Installation for procedures (remove only the
upper section of the fuel pump module). Measure the
resistance across the sending unit terminals. With
float in up position, resistance should be 20 ohms (+/-
5%). With float in down position, resistance should be
270 ohms (+/- 5%).
REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the lower sec-
tion of the fuel pump module. The lower section of
the fuel pump module is located within the fuel tank.
(1) Remove lower section of fuel pump module
from fuel tank. Refer to Fuel Pump Module Removal/
Installation.
(2) To remove sending unit from pump module, lift
on plastic locking tab (Fig. 8) while sliding sending
unit upwards.
(3) Disconnect 4±wire electrical connector (Fig. 9)
from bottom of upper section of fuel pump module.
Separate necessary sending unit wiring.
Fig. 8 FUEL LEVEL SENDING UNIT
1 - LIFT TAB HERE FOR REMOVAL
2 - FUEL LEVEL SENDING UNIT
3 - LOWER SECTION OF PUMP MODULE
KJFUEL DELIVERY 14 - 9