2002 JEEP LIBERTY transfer case

Component Page
Sunroof Switch.................... 8Wa-80-95
Tailgate Cylinder Lock Switch......... 8Wa-80-95
Tailgate Flip-Up Ajar Switch.......... 8Wa-80-95
Tailgate Lock Motor/Ajar Switch....... 8Wa-80-95
Throttle Position Sensor............. 8Wa-80-96
Trailer Tow Brake Lamp Relay........ 8Wa-80-96
Trailer Tow Circuit Breaker.......... 8Wa-80-96
Trailer Tow Connector............... 8Wa-80-96
Trailer Tow Left Turn Relay.......... 8Wa-80-97Component Page
Trailer Tow Relay.................. 8Wa-80-97
Trailer Tow Right Turn Relay......... 8Wa-80-97
Transfer Case Position Sensor......... 8Wa-80-97
Transmission Control Module (3.7L).... 8Wa-80-98
Transmission Solenoid/TRS Assembly
(3.7L).......................... 8Wa-80-99
Washer Fluid Level Switch........... 8Wa-80-99
Washer Pump.................... 8Wa-80-100
Water In Fuel Sensor (Diesel)........ 8Wa-80-100
8Wa - 80 - 4 8W-80 CONNECTOR PIN-OUTSKJ

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

TRAILER TOW LEFT TURN RELAY-5WAY
CAV CIRCUIT FUNCTION
30 L73 16PK/WT LEFT TURN SIGNAL
85 Z149 18BK/LB GROUND
86 L63 18DG/RD LEFT TURN SIGNAL
87 L76 16BK/OR TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A L95 16DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
87 L76 16BK/OR TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRAILER TOW RELAY-5WAY
CAV CIRCUIT FUNCTION
30 F71 14RD FUSED B(+)
85 Z149 18BK/LB GROUND
86 V23 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
87A - -
87 F73 14YL TRAILER TOW RELAY OUTPUT
TRAILER TOW RIGHT TURN RELAY-5WAY
CAV CIRCUIT FUNCTION
30 L74 16PK/BK RIGHT TURN SIGNAL
85 Z149 18BK/LB GROUND
86 L62 18BR/RD RIGHT TURN SIGNAL
87A L95 16DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
87 L76 16BK/OR TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRANSFER CASE POSITION SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K77 20BR/WT (DIESEL) TRANSFER CASE POSITION SENSOR INPUT
1 K77 18BR/WT (GAS) TRANSFER CASE POSITION SENSOR INPUT
2 K4 18BK/LB SENSOR GROUND
KJ8W-80 CONNECTOR PIN-OUTS8Wa-80-97

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Siren (BUX) Right Front Side of Engine
Compartment28
Speed Control Servo BK Right Rear Side of Engine
Compartment27
Sunroof Motor LG Overhead Console N/S
Sunroof Switch BK Overhead Console N/S
Tailgate Cylinder Lock Switch LG In Tailgate 46
Tailgate Flip-Up Ajar Switch GY In Tailgate 46
Tailgate Lock Motor/Ajar Switch BK In Tailgate 46
Throttle Position Sensor WT On Throttle Body 1
Trailer Tow Brake Lamp Relay Right Quarter Panel 47
Trailer Tow Circuit Breaker Right Quarter Panel N/S
Trailer Tow Connector BK At Trailer Hitch 47, 48
Trailer Tow Right Turn Relay Right Quarter Panel 47
Trailer Tow Relay Right Quarter Panel 47
Trailer Tow Left Turn Relay Right Quarter Panel 47
Transfer Case Position Sensor BK Rear Side of Transmission 5, 7, 11, 12, 22
Transmission Control Module (3.7L)
(LHD)BK Right Rear Side of Engine
Compartment8, 9
Transmission Control Module (3.7L)
(RHD)BK Left Rear Side of Engine
Compartment10
Transmission Solenoid/TRS
Assembly (3.7L)GY Left Side of Transmission 5
Under Hood Lamp BK Underside of Hood 24
Washer Fluid Level Switch LG At Washer Fluid Reservoir 28
Water In Fuel Sensor (Diesel) Left Rear Side of Engine
Compartment19
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Left Side of Engine Compartment 8, 9, 10, 14, 19
G101 (2.4L) Left Side of Engine Compartment 11
G102 (LHD) Right Rear Side of Engine Compartment 9
G102 (RHD) Left Rear Side of Engine Compartment 10
G103 (3.7L) Right Front Side of Engine 4
G103 (Diesel) Right Front Side of Engine 20
G104 Near Engine Control Module C2 19
G105 Left Side of Engine Compartment N/S
G106 Left Side of Engine Compartment N/S
G110 Left Side of Engine Compartment 30
G111 Left Front Side of Engine Compartment 29
G112 Left Front Side of Engine Compartment 29
G200 Near Body Control Module N/S
KJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION8Wa-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(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)

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA SUPPORT
REMOVAL.............................3
INSTALLATION..........................3
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 3
SPECIFICATIONS - TORQUE.............6
FRONT SKID PLATE
REMOVAL.............................6
INSTALLATION..........................6
ENGINE CRADLE CROSSMEMBER
REMOVAL.............................6
INSTALLATION..........................6TRANSFER CASE SKID PLATE
REMOVAL.............................7
INSTALLATION..........................7
REAR CROSSMEMBER
REMOVAL.............................7
INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................8
INSTALLATION..........................8
REAR TOW HOOK
REMOVAL.............................8
INSTALLATION..........................8
TRAILER HITCH
REMOVAL.............................9
INSTALLATION..........................9
FUEL TANK SKID PLATE
REMOVAL.............................9
INSTALLATION..........................9
FRONT FASCIA
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Raise and support vehicle.
(3) Remove the front wheel opening flare moldings.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL
OPENING FLARE MOLDINGS - REMOVAL)
(4) Remove the four screws through the lower air
dam (Fig. 1).
(5) Disconnect the electrical connectors:
²Fascia to grille opening reinforcement. (Fig. 1)
²Side repeater lights, both sides, if equipped.
(Fig. 2)
(6) Remove the six push pins from the grill sup-
port.
(7) Remove the rivets attaching the air dam to the
wheelhouse splash shield.
(8) Release the support tabs beneath the head-
lamps.
(9) Release the inner support clips from within the
fascia between the lights (Fig. 2).
(10) Remove the fascia.
Fig. 1 FRONT FASCIA
1 - ELECTRICAL CONNECTOR
2 - PUSH PINS
3 - FRONT FASCIA ASSEMBLY
4 - LOWER SCREWS
5 - PLASTIC RIVETS (2)
6 - INNER SUPPORT CLIPS
7 - SUPPORT TABS
KJFRAMES & BUMPERS 13 - 1