2002 JEEP LIBERTY clutch

(9) Slide actuator off pivot pin.
(10) Disconnect clutch interlock safety switch
wires.(11) Remove clutch hydraulic linkage through
engine compartment.
INSTALLATION
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Be sure reservoir cover on clutch master cylin-
der is tight to avoid spills.
(2) Position clutch linkage components in vehicle.
Work connecting line and slave cylinder downward
past engine and adjacent to clutch housing.
(3) Position clutch master cylinder on dash panel.
(4) Attach clutch master cylinder actuator to pivot
pin on clutch pedal.
(5) Install and tighten clutch master cylinder
attaching nuts to 38 N´m (28 ft. lbs.).
(6) Raise vehicle.
(7) Insert slave cylinder push rod through clutch
housing opening and into release lever. Be sure cap
on end of rod is securely engaged in lever. Check this
before installing cylinder attaching nuts.
(8) Install and tighten slave cylinder attaching
nuts to 23 N´m (17 ft. lbs.).
(9) Secure clutch fluid line in body and transmis-
sion clips.
(10) Lower vehicle.
(11) Connect clutch interlock safety switch wires.
MASTER CYLINDER
INSPECTION
The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are pre-filled with fluid at
the factory during assembly operations.
The hydraulic system should not require additional
fluid under normal circumstances.The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling or remov-
ing fluid from the reservoir.
Clutch fluid level is checked at the master cylinder
reservoir. An indicator ring is provided on the outside
of the reservoir. With the cap and diaphragm
removed, fluid level should not be above indicator
ring.
To avoid contaminating the hydraulic fluid during
inspection, wipe reservoir and cover clean before
removing the cap.
Fig. 6 SLAVE CYLINDER
1 - CLUTCH SLAVE CYLINDER
Fig. 7 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
KJCLUTCH 6 - 9
LINKAGE (Continued)

CLUTCH PEDAL
REMOVAL
(1) Remove steering column lower cover and knee
blocker for access.
(2) Disconnect clutch pedal position switch wires.
(3) Disengage captured bushing lock tabs attach-
ing clutch master cylinder actuator to pedal pivot.
(4) Remove nuts attaching pedal and bracket to
dash panel and upper cowl support (Fig. 8).
(5) Separate pedal assemble from vehicle.
INSTALLATION
(1) Place clutch pedal and bracket over studs on
dash panel and cowl support.
(2) Install nuts to attach pedal and bracket to
dash panel and upper cowl support. Tighten nuts to
39 N´m (29 ft. lbs.) torque
(3) Engage captured bushing and actuator on
brake pedal pivot.
(4) Connect clutch pedal position switch wires.
CLUTCH SWITCH OVERRIDE
RELAY
DESCRIPTION
The clutch pedal position switch override relay is
located in the Power Distribution Center (PDC).
Refer to PDC cover label for location within PDC.
OPERATION
Refer to Clutch Pedal Position Switch Operation
for information.
REMOVAL
The Clutch Switch Override Relay is located in the
Power Distribution Center (PDC) (Fig. 9). Refer to
label on PDC cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The Clutch Switch Override Relay is located in the
Power Distribution Center (PDC). Refer to label on
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
Fig. 8 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
Fig. 9 POWER DISTRIBUTION CENTER (PDC)
1 - BATTERY
2 - PDC
3 - PDC COVER
6 - 10 CLUTCHKJ

CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The clutch pedal position switch is located under
the instrument panel. It is attached to the clutch
master cylinder push rod (Fig. 10). The wiring har-
ness connection for the switch is made in the engine
compartment (Fig. 10).
The clutch pedal position switch override relay is
located in the Power Distribution Center (PDC).
Refer to PDC cover label for location within PDC.
OPERATION
The clutch pedal position switch is used to prevent
starter motor engagement unless the clutch pedal is
depressed.
4WD Feature:The clutch pedal position switch
override relay will inhibit operation of the position
switch when the vehicle transfer case is in the four±
wheel±drive (4WD) low-range position (only). This
feature will allow operation of the starter motor,
without the need for depressing the clutch pedal, for
certain off-road applications. If any Diagnostic Trou-
ble Codes (DTC's) for either the override relay or
transfer case switch are stored, the override relay
feature will be inhibited.
An input from this switch is also used to either
shut down and/or prevent operation of the speed con-
trol system when the clutch pedal is depressed.
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH
(1) Locate switch 2±wire electrical connector in
engine compartment (Fig. 10). Disconnect wiring at
this point.
(2) Check for switch continuity with an ohmmeter
while operating clutch pedal up and down. Continu-ity should be broken and reapplied each time pedal is
pressed.
(3) If continuity is not present, or is always
present at any pedal position, replace switch. Switch
is not serviced separately. Replace clutch master
cylinder.
Fig. 10 CLUTCH PEDAL POSITION SWITCH
1 - CLUTCH MASTER CYLINDER
2 - CLUTCH PEDAL POSITION SWITCH
3 - CLUTCH PEDAL PIN
4 - MASTER CYLINDER PUSHROD
5 - ELECTRICAL CONNECTION (IN ENGINE COMPARTMENT)
KJCLUTCH 6 - 11

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)

through the radiator. The thermostat uses a stub
shaft located at the rear of the thermostat to control
flow through the bypass gallery.
OPERATION - WATER PUMP
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
REMOVAL
The water pump on 3.7L engines is bolted directly
to the engine timing chain case cover.
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan/viscous fan drive assembly from
water pump (Fig. 18) (Refer to 7 - COOLING/EN-
GINE/FAN DRIVE VISCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
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). SNAP-ON CLAMP TOOL (NUMBER HPC-20)MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(4) If water pump is being replaced, do not unbolt
fan blade assembly from thermal viscous fan drive.
(5) Remove two fan shroud-to-radiator screws, Dis-
connect the coolant overflow hose.
(6) Remove upper fan shroud and fan blade/viscous
fan drive assembly from vehicle.
(7) After removing fan blade/viscous fan drive
assembly,do notplace thermal viscous fan drive in
horizontal position. If stored horizontally, silicone
fluid in viscous fan drive could drain into its bearing
assembly and contaminate lubricant.
(8) Remove accessory drive belt (Fig. 19) (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) Remove lower radiator hose clamp and remove
lower hose at water pump.
(10) Remove seven water pump mounting bolts
and one stud bolt.
Fig. 18 Viscous Fan and Fan Drive 3.7L
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
Fig. 19 Automatic Belt TensionerÐ3.7L
1 - AUTOMATIC TENSIONER
2 - WATER PUMP PULLEY
7 - 30 ENGINEKJ
WATER PUMP (Continued)

CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(11) Remove water pump and gasket. Discard gas-
ket.
CLEANING
Clean the gasket mating surface. Use caution not
to damage the gasket sealing surface.
INSPECTION
Inspect the water pump assembly for cracks in the
housing, Water leaks from shaft seal, Loose or rough
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.
INSTALLATION
The water pump on 3.7L engines is bolted directly
to the engine timing chain case cover.
(1) Clean gasket mating surfaces.
(2) Using a new gasket, position water pump and
install mounting bolts as shown. (Fig. 20). Tighten
water pump mounting bolts to 54 N´m (40 ft. lbs.)
torque.
(3) Spin water pump to be sure that pump impel-
ler does not rub against timing chain case/cover.
(4) Connect radiator lower hose to water pump.
(5) Relax tension from belt tensioner. Install drive
belt (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).CAUTION: When installing the serpentine accessory
drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 21) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
(6) Position upper fan shroud and fan blade/vis-
cous fan drive assembly.
(7) Be sure the upper and lower portions of the fan
shroud are firmly connected. All air must flow
through the radiator.
(8) Install two fan shroud-to-radiator screws.
(9) Be sure of at least 25 mm (1.0 inches) between
tips of fan blades and fan shroud.
(10) Install fan blade/viscous fan drive assembly to
water pump shaft (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(11) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Connect negative battery cable.
(13) Start and warm the engine. Check for leaks.
Fig. 20 Water Pump InstallationÐ3.7L
1 - WATER PUMP
2 - TIMING CHAIN COVER
Fig. 21 Belt Routing 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
KJENGINE 7 - 31
WATER PUMP (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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.
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.
KJCOOLING - 2.4L7s-7
COOLING - 2.4L (Continued)

²The fuel pump is energized through the fuel
pump relay by the PCM. The fuel pump will operate
for approximately three seconds unless the engine is
operating or the starter motor is engaged.
²The O2S sensor heater element is energized via
the ASD or O2S heater relay. The O2S sensor input
is not used by the PCM to calibrate air-fuel ratio dur-
ing this mode of operation.
ENGINE START-UP MODE
This is an Open Loop mode. The following actions
occur when the starter motor is engaged.
The PCM receives inputs from:
²Battery voltage
²Engine coolant temperature sensor
²Crankshaft position sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal
The PCM monitors the crankshaft position sensor.
If the PCM does not receive a crankshaft position
sensor signal within 3 seconds of cranking the
engine, it will shut down the fuel injection system.
The fuel pump is activated by the PCM through
the fuel pump relay.
Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
the injection sequence and injector pulse width by
turning the ground circuit to each individual injector
on and off.
The PCM determines the proper ignition timing
according to input received from the crankshaft posi-
tion sensor.
ENGINE WARM-UP MODE
This is an Open Loop mode. During engine warm-
up, the PCM receives inputs from:
²Battery voltage
²Crankshaft position sensor
²Engine coolant temperature sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal
²Park/neutral switch (gear indicator signalÐauto.
trans. only)
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
Based on these inputs the following occurs:
²Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
the injection sequence and injector pulse width by
turning the ground circuit to each individual injector
on and off.²The PCM adjusts engine idle speed through the
idle air control (IAC) motor and adjusts ignition tim-
ing.
²The PCM operates the A/C compressor clutch
through the A/C compressor clutch relay. This is done
if A/C has been selected by the vehicle operator and
specified pressures are met at the high and low±pres-
sure A/C switches. Refer to Heating and Air Condi-
tioning for additional information.
²When engine has reached operating tempera-
ture, the PCM will begin monitoring O2S sensor
input. The system will then leave the warm-up mode
and go into closed loop operation.
IDLE MODE
When the engine is at operating temperature, this
is a Closed Loop mode. At idle speed, the PCM
receives inputs from:
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
²Battery voltage
²Crankshaft position sensor
²Engine coolant temperature sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Camshaft position sensor signal
²Battery voltage
²Park/neutral switch (gear indicator signalÐauto.
trans. only)
²Oxygen sensors
Based on these inputs, the following occurs:
²Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
injection sequence and injector pulse width by turn-
ing the ground circuit to each individual injector on
and off.
²The PCM monitors the O2S sensor input and
adjusts air-fuel ratio by varying injector pulse width.
It also adjusts engine idle speed through the idle air
control (IAC) motor.
²The PCM adjusts ignition timing by increasing
and decreasing spark advance.
²The PCM operates the A/C compressor clutch
through the A/C compressor clutch relay. This is done
if A/C has been selected by the vehicle operator and
specified pressures are met at the high and low±pres-
sure A/C switches. Refer to Heating and Air Condi-
tioning for additional information.
CRUISE MODE
When the engine is at operating temperature, this
is a Closed Loop mode. At cruising speed, the PCM
receives inputs from:
²Air conditioning select signal (if equipped)
²Air conditioning request signal (if equipped)
8E - 12 ELECTRONIC CONTROL MODULESKJ
POWERTRAIN CONTROL MODULE (Continued)