2002 JEEP LIBERTY timing chain cover

(20) After installing all chains, it is recommended
that the idler gear end play be checked (Fig. 112).
The end play must be within 0.10±0.25 mm (0.004±
0.010 in.). If not within specification, the idler gear
must be replaced.
(21) Install timing chain cover and crankshaft
damper. Refer to procedures.
(22) Install cylinder head covers. Refer to proce-
dures.
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.(23) Coat the large threaded access plug with
MopartThread Sealant with Teflon, then install
into the right cylinder head and tighten to 81 N´m
(60 ft. lbs.).
(24) Install the oil fill housing.
(25) Install access plug in left cylinder head.
(26) Install power steering pump.
(27) Fill cooling system.
(28) Connect negative cable to battery.
Fig. 111 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKETFig. 112 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
9 - 82 ENGINE - 3.7LKJ
TIMING BELT/CHAIN AND SPROCKET(S (Continued)

CRANKSHAFT
DESCRIPTION.........................32
OPERATION...........................33
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................33
REMOVAL.............................33
INSPECTION..........................34
INSTALLATION.........................34
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING.............................35
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................37
INSTALLATION.........................37
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................38
INSTALLATION.........................39
PISTON & CONNECTING ROD
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................40
INSTALLATION.........................41
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................42
VIBRATION DAMPER
REMOVAL.............................43
INSTALLATION.........................43
STRUCTURAL COLLAR
REMOVAL.............................44
INSTALLATION.........................44
ENGINE MOUNTING
DESCRIPTION.........................44
FRONT MOUNT
REMOVAL.............................44
INSTALLATION.........................44
REAR MOUNT
REMOVAL.............................45
INSTALLATION.........................45
LUBRICATION
DESCRIPTION.........................46
OPERATION...........................46
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE CHECKING.................46
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............47
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................47
OIL FILTER
DESCRIPTION.........................47
REMOVAL.............................47
INSTALLATION.........................47
OIL PAN
REMOVAL.............................48INSTALLATION.........................48
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................48
OPERATION...........................48
OIL PUMP
REMOVAL.............................49
DISASSEMBLY.........................49
CLEANING............................49
INSPECTION..........................50
ASSEMBLY............................50
INSTALLATION.........................50
INTAKE MANIFOLD
DESCRIPTION.........................51
OPERATION...........................51
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................51
REMOVAL.............................52
INSPECTION..........................52
INSTALLATION.........................52
EXHAUST MANIFOLD
DESCRIPTION.........................53
OPERATION...........................53
REMOVAL.............................53
CLEANING............................53
INSPECTION..........................53
INSTALLATION.........................53
TIMING BELT COVER(S)
REMOVAL.............................53
INSTALLATION.........................53
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............55
REMOVAL - CRANKSHAFT SPROCKET....55
CLEANING............................55
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 56
INSTALLATION - TIMING BELT...........56
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................59
INSTALLATION.........................59
BALANCE SHAFT
DESCRIPTION.........................59
OPERATION...........................59
REMOVAL.............................60
INSTALLATION
BALANCE SHAFT TIMING...............61
BALANCE SHAFT CARRIER
REMOVAL.............................64
INSTALLATION.........................64
BALANCE SHAFT CHAIN
REMOVAL.............................64
INSTALLATION.........................64
9s - 2 ENGINEKJ

Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove intake manifold.
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump and set aside.
Do not disconnect lines.
(11) Remove accessory drive bracket
(12) Remove ignition coil and wires from engine.
(13) Disconnect cam sensor and fuel injector wir-
ing connectors.
(14) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(15) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(16) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(17) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(18) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL).
(19) Remove cylinder head bolts in REVERSE
sequence of tightening.
(20) Remove cylinder head from engine block.
(21) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
9s - 20 ENGINEKJ
CYLINDER HEAD (Continued)

²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install accessary drive bracket.
(13) Install power steering pump to cylinder head.
(14) Raise vehicle and install the exhaust pipe to
the manifold.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install heater tube support bracket to cylinder
head.
(17) Install intake manifold.
(18) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(19) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(20) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 12).
(3) Remove camshaft sprockets.
(4) Remove exhaust camshaft target ring.
(5) Remove exhaust camshaft sensor.
CAUTION: Inspect sensor and target ring for exces-
sive wear. Clean sensor face and install new spacer
pad.
(6) Remove rear timing belt cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(7) Remove camshaft seal using Special Tool
C-4679-A (Fig. 13).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
NOTE: Clean and inspect sensor and target ring for
excessive wear. Clean sensor face and always
install a new spacer pad.
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
14).
Fig. 10 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 11 Cylinder Head Tightening Sequence
9s - 22 ENGINEKJ
CYLINDER HEAD (Continued)

(3) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
NOTE: Target ring tab should provide posative
snap-on fit on the camshaft.
(4) Install exhaust camshaft target ring with the
wordFRONTfacing forward.
(5) Install exhaust camshaft sensor.
(6) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.).
(7) Install timing belt and front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAINAND SPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
CAMSHAFT(S)
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 15).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the exhaust camshaft on the front of the cylinder
head. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
STANDARD PROCEDURE - CAMSHAFT
END-PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTcam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 16).
(4) Move camshaft as far forward as it will go.
(5) Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
(6) If end play is excessive, check cylinder head
and camshaft for wear; replace as necessary.
Fig. 12 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 13 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
Fig. 14 Camshaft Seal - Installation
1 - SPECIAL TOOL MD 998306
KJENGINE9s-23
CAMSHAFT OIL SEAL(S) (Continued)

REMOVAL
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Remove camshaft position sensor and camshaft
target magnet. (Refer to 8 - ELECTRICAL/IGNI-
TION CONTROL/CAMSHAFT POSITION SENSOR -
REMOVAL)
(3) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)(4) Remove camshaft sprockets and timing belt
rear cover. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - REMOVAL)
(5) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 17).
(6) Loosen the camshaft bearing cap attaching
fasteners in sequence shown (Fig. 18) one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(7) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
(8) Remove camshafts from cylinder head.
NOTE: If removing rocker arms, identify for reinstal-
lation in the original position.
CLEANING
Clean camshaft with a suitable solvent.
Fig. 15 Camshafts
CAM PLUG - NOT SHOWN
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
Fig. 16 Camshaft End Play - Typical
Fig. 17 Camshaft Bearing Cap Identification
Fig. 18 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
9s - 24 ENGINEKJ
CAMSHAFT(S) (Continued)

INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 19). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.
(3) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 19) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubricate all camshaft bearing journals, rocker
arms and camshaft lobes.
(2) Install all rocker arms in original positions, if
reused.
(3) Position camshafts on cylinder head bearing
journals. Install right and left camshaft bearing caps
No.2±5andright No. 6. Tighten M6 fasteners to 12
N´m (105 in. lbs.) in sequence shown in (Fig. 20).
(4) Apply MopartGasket Maker to No. 1 and No.
6 bearing caps (Fig. 21). Install bearing caps and
tighten M8 fasteners to 28 N´m (250 in. lbs.).NOTE: Bearing end caps must be installed before
seals can be installed.
(5) Install camshaft oil seals. (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSHAFT OIL
SEAL(S) - INSTALLATION)
(6) Install camshaft target magnet and camshaft
position sensor.
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
Fig. 19 Checking Camshaft(s) for Wear
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
Fig. 20 Camshaft Bearing Cap Tightening Sequence
Fig. 21 Camshaft Bearing Cap Sealing
1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET
MAKER
KJENGINE9s-25
CAMSHAFT(S) (Continued)

OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 40).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Remove flex plate and crankshaft rear oil seal.
(3) Mount engine on a repair stand.
(4) Drain engine oil and remove oil filter.
(5) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(6) Remove the timing belt covers. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)(7) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(8) Remove the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL)
(9) Remove balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
(10) Remove all bedplate bolts from the engine
block (Fig. 41).
(11) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(12) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
(13) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
Fig. 39 Crankshaft - Typical
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 40 CHECKING CRANKSHAFT END PLAY
Fig. 41 Bedplate Bolt Tightenening Sequence
KJENGINE9s-33
CRANKSHAFT (Continued)