2002 JEEP LIBERTY CRANK SHAFT

EGR SOLENOID (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
1 A71 18DG/RD FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K35 18GY/YL EGR SOLENOID CONTROL
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
1 Z108 14BK/DG GROUND
2 Z108 14BK/DG GROUND
3 K20 18DG GENERATOR FIELD CONTROL
4 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
5 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
6- -
7 D25 20VT/YL PCI BUS
8 K944 20BK/LB CAMSHAFT POSITION SENSOR GROUND
9 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 - -
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K81 20VT/TN ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20BK/VT FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 F92 20YL/BR BATTERY SENSE (+)
20 Z109 20BK/DB BATTERY SENSE (-)
21 K4 20BK/LB SENSOR GROUND
22 F1 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 K6 20VT/WT SENSOR REFERENCE VOLTAGE B
24 K3 20LB/BK CRANKSHAFT POSITION SENSOR SIGNAL 2
25 - -
26 - -
27 - -
28 - -
29 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT
30 G60 20GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
31 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
32 K118 20PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND
35 K852 20VT/WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
36 - -
37 - -
38 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
39 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Y101 20BK/OR CRANKSHAFT POSITION SENSOR SHIELD
43 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL 1
KJ8W-80 CONNECTOR PIN-OUTS8Wa-80-55

POWER WINDOW MASTER SWITCH (MIDLINE/HIGHLINE) - LT. GRAY 14 WAY
CAV CIRCUIT FUNCTION
1- -
2 Q1 16YL POWER WINDOW SWITCH FEED
2 Q1 16YL POWER WINDOW SWITCH FEED
3- -
4 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
5 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
6 Q28 14DG/WT RIGHT REAR WINDOW DRIVER DOWN
7 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
8- -
9 Q21 14WT LEFT FRONT WINDOW DRIVER DOWN
10 F81 12TN FUSED B(+)
11 Q11 14LB LEFT FRONT WINDOW DRIVER UP
12 Q12 14BR RIGHT FRONT WINDOW DRIVER UP
13 Q22 14VT/WT RIGHT FRONT WINDOW DRIVER DOWN
14 Z238 12BK/WT GROUND
POWERTRAIN CONTROL MODULE-C1 (2.4L) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1- -
2 F1 18DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
3- -
4 K4 18BK/LB SENSOR GROUND
5- -
6- -
7 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9- -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 1 DRIVER
12 K10 18DB/OR POWER STEERING PRESSURE SWITCH SENSE
13 - -
14 K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5 VOLT SUPPLY
18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 3 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
22 A14 16RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 - -
27 K1 18DG/RD MANIFOLD ABOLUTE PRESSURE SENSOR SIGNAL
28 - -
29 - -
30 - -
31 Z107 14BK/DB GROUND
32 Z107 14BK/DB GROUND
KJ8W-80 CONNECTOR PIN-OUTS8Wa-80-81

POWERTRAIN CONTROL MODULE-C1 (3.7L) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 K93 14TN/OR COIL ON PLUG DRIVER NO. 3
2 F1 18DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 K94 14TN/LG COIL ON PLUG DRIVER NO. 4
4 K4 18BK/LB SENSOR GROUND
5 K96 14TN/LB COIL ON PLUG DRIVER NO. 6
6 T41 18BK/WT (A/T) PARK/NEUTRAL POSITION SWITCH SENSE
7 K91 14TN/RD COIL ON PLUG DRIVER NO.1
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9- -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 1 DRIVER
12 K10 18DB/OR POWER STEERING PRESSURE SWITCH SENSE
13 T141 18 YL/RD (M/T) FUSED IGNITION SWITCH OUTPUT (START)
13 F45 18YL/BR (A/T) FUSED IGNITION SWITCH OUTPUT (START)
14 K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K7 18OR 5 VOLT SUPPLY
18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 3 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 K95 14TN/DG COIL ON PLUG DRIVER NO. 5
22 A14 16RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MANIFOLD ABOLUTE PRESSURE SENSOR SIGNAL
28 - -
29 K341 18TN/WT OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z107 14BK/DB GROUND
32 Z107 14BK/DB GROUND
POWERTRAIN CONTROL MODULE-C2 (GAS) - WHITE 32 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
6 K38 18GY (3.7L) FUEL INJECTOR NO. 5 DRIVER
7- -
8- -
9 K92 14TN/PK (3.7L) COIL ON PLUG DRIVER NO. 2
9 K17 18DB/TN (2.4L) IGNITION COIL NO. 2 DRIVER
10 K20 18DG GENERATOR FIELD
11 - -
12 K58 18BR/DB (3.7L) FUEL INJECTOR NO. 6 DRIVER
8Wa - 80 - 82 8W-80 CONNECTOR PIN-OUTSKJ

TRANSMISSION CONTROL MODULE (3.7L) - BLACK 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 T4 18PK/OR TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4- -
5- -
6 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18PK SCI TRANSMIT
8 F45 18YL/BR FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 F1 18DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 18PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
18 T591 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T20 18LB LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T38 18VT/TN LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
36 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
37 Z113 14BK/YL GROUND
38 T39 18GY/LB 5 VOLT SUPPLY
39 Z113 14BK/YL GROUND
40 T140 18VT/LG MS SOLENOID CONTROL
41 T411 18WT/PK TRS T41 SENSE
42 T42 18VT/WT TRS T42 SENSE
43 D25 18VT/YL PCI BUS
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T147 18LB 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
51 K4 18BK/LB SENSOR GROUND
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z112 14BK GROUND
8Wa - 80 - 98 8W-80 CONNECTOR PIN-OUTSKJ

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Coil On Plug No.5 (3.7L) BK Left Side of Engine Near
Fuel Injector No.51
Coil On Plug No.6 (3.7L) BK Right Side of Engine Near
Fuel Injector No.62
Coil Rail (2.4L) BK Right Side of Engine 11, 12
Combination Flasher WT Under Left Side of
Instrument PanelN/S
Compass Mini-Trip Computer BK At Overhead Console N/S
Controller Antilock Brake BK Left Side of Engine
Compartment30
Crankshaft Position Sensor (2.4L) BK Top of Engine N/S
Crankshaft Position Sensor (3.7L) BK Right Lower Side of Engine 4
Crankshaft Position Sensor (Diesel) BK Right Rear Side of Engine 17
Data Link Connector BK Under Center of Instrument
PanelN/S
Diagnostic Junction Port BK Under Center of Instrument
Panel49
Dome Lamp (Base) BK On Headliner N/S
Driver Airbag Squib 1 GY In Steering Wheel N/S
Driver Airbag Squib 2 BK In Steering Wheel N/S
Driver Seat Belt Switch LG At Drive Seat N/S
Driver Seat Belt Tensioner (LHD) YL Lower Left B-Pillar 35
Driver Seat Belt Tensioner (RHD) YL Lower Right B-Pillar 39
EGR Solenoid Right Rear Side of Engine
Compartment27
Engine Control Module C1 BK Left Rear Side of Engine
Compartment19
Engine Control Module C2 BK Left Rear Side of Engine
Compartment19
Engine Coolant Level Sensor (Diesel) LG Rear Side of Engine
Compartment18
Engine Coolant Temperature Sensor
(Diesel)BK Left Side of Engine 20
Engine Coolant Temperature Sensor
(Gas)BK Front Side of Engine 2
Engine Oil Pressure Sensor (2.4L) BK Top of Engine N/S
Engine Oil Pressure Sensor (3.7L) BK Left Front Side of Engine 3
Engine Oil Pressure Sensor (Diesel) BK Right Rear Side of Engine 17
Engine Starter Motor Right Front Side of Engine 20
Evap/Purge Solenoid BK At Solenoid N/S
Flip-Up Glass Release Motor BK In Tailgate 46
Flip-Up Glass Release Switch WT In Tailgate 46
Front Washer Pump BK Right Front Side of Engine
Compartment28
Front Wiper Motor (LHD) BK Left Side of Cowl 24
8Wa - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONKJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

ENGINE BLOCK
DESCRIPTION.........................39
STANDARD PROCEDURE - CYLINDER BORE
HONING............................39
CLEANING............................39
INSPECTION..........................40
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING - FITTING...............40
CRANKSHAFT
DESCRIPTION.........................42
REMOVAL.............................43
INSPECTION..........................43
INSTALLATION.........................43
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING - FITTING...............45
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................46
INSTALLATION.........................47
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................48
INSTALLATION.........................48
FLEX PLATE
REMOVAL.............................49
INSTALLATION.........................49
PISTON & CONNECTING ROD
DESCRIPTION.........................49
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING . . . 49
STANDARD PROCEDURE - PISTON
FITTING.............................50
REMOVAL.............................50
CLEANING............................51
INSPECTION..........................51
INSTALLATION.........................51
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................54
INSTALLATION.........................55
STRUCTURAL COVER
DESCRIPTION.........................55
OPERATION...........................55
REMOVAL.............................55
INSTALLATION.........................55
FRONT MOUNT
REMOVAL.............................56
INSTALLATION.........................57
REAR MOUNT
REMOVAL.............................57
INSTALLATION.........................57
LUBRICATION
DESCRIPTION.........................57
OPERATION...........................58DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK...............................60
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE..........................60
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS.........................61
OIL
STANDARD PROCEDURE - ENGINE OIL.....61
OIL FILTER
REMOVAL.............................63
INSTALLATION.........................63
OIL PAN
DESCRIPTION.........................63
REMOVAL.............................63
CLEANING............................63
INSPECTION..........................63
INSTALLATION.........................64
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................65
OPERATION...........................65
REMOVAL.............................65
INSTALLATION.........................65
OIL PUMP
REMOVAL.............................65
DISASSEMBLY.........................65
INSPECTION..........................66
ASSEMBLY............................67
INSTALLATION.........................67
INTAKE MANIFOLD
DESCRIPTION.........................68
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................68
REMOVAL.............................68
INSTALLATION.........................69
EXHAUST MANIFOLD
DESCRIPTION.........................69
REMOVAL.............................69
INSTALLATION.........................70
VALVE TIMING
DESCRIPTION.........................71
OPERATION...........................71
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR.......71
SERVICE PROCEDURES...............72
BALANCE SHAFT
REMOVAL.............................74
INSTALLATION.........................74
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................74
INSTALLATION.........................76
IDLER SHAFT
REMOVAL.............................77
INSTALLATION.........................77
TIMING BELT/CHAIN AND SPROCKET(S
REMOVAL.............................77
INSPECTION..........................79
INSTALLATION.........................80
9 - 2 ENGINE - 3.7LKJ

ENGINE - 3.7L
DESCRIPTION
The 3.7 liter (226 CID) six-cylinder engine is an
90É single overhead camshaft engine. The cast iron
cylinder block is made up of two different compo-
nents; the first component is the cylinder bore and
upper block, the second component is the bedplate
that comprises the lower portion of the cylinder block
and houses the lower half of the crankshaft mainbearings. The cylinders are numbered from front to
rear with the left bank being numbered 1,3,and 5
and the right bank being numbered 2,4, and 6. The
firing order is 1±6±5±4±3±2. The engine serial num-
ber is located at the right front side of the engine
block
3.7 L ENGINE
KJENGINE - 3.7L 9 - 3

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Clean or replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
8. Excessive runout of valve seats
on valve faces.8. Service valves and valve seats.
(Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
ENGINE VIBRATION 1. Counter Balance Shaft not timed
properly1. Refer to Engine Timing in this
section
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Low oil pressure. 2. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
3. Thin or diluted oil. 3. Change oil and filter.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.7. Tighten to correct torque
9 - 6 ENGINE - 3.7LKJ
ENGINE - 3.7L (Continued)