2002 JEEP LIBERTY Gasket install

the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 124 KPA (18 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack in engine. Repair
as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
KJCOOLING 7 - 5
COOLING (Continued)

(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator
is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
ment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE
Drain the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). Remove the thermostat
housing and thermostat. Install the thermostat hous-
ing. Disconnect the radiator upper hose from the
radiator and attach the flushing gun to the hose. Dis-
connect the radiator lower hose from the water
pump. Attach a lead away hose to the water pump
inlet fitting.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
water. When the engine is filled, apply air in short
blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo-
stat housing (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT - REMOVAL).
Install the thermostat and housing with a replace-
ment gasket (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT -INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
BracketÐBolt
2.4L - Ð -
4.7L 41 30 Ð
Automatic Belt Tensioner
PulleyÐ
Bolt
(3.7L) 61 45 Ð
Block HeaterÐBolt
2.4L - Ð -
3.7L 2 Ð 17
Condenser to Radiator Bolts 8 70
Coolant Overflow Bottle to
Plenum mounting bolts - 2.4L
only8.5 75
Coolant Pressure Bottle to
Plenum mounting bolts -3.7L
only8.5 75
Electric Fan to Fan Shroud
bolts5.5 50
Fan Blade Assy. to Viscous
Drive
Bolts 3.7L 23 Ð 210
Fan Shroud to Radiator
Mounting Bolts8Ð70
Radiator Upper Isolator to
Crossmember - Bolts 9.5 Ð 85
Thermostat HousingÐBolts
2.4L - - Ð
4.7L 13 Ð 115
Water PumpÐBolts
2.4L Ð Ð Ð
4.7L 54 40 Ð
KJCOOLING 7 - 13
COOLING (Continued)

INSTALLATION - 3.7L ENGINE
(1) Clean mating areas of timing chain cover and
thermostat housing.
(2)
Install thermostat (spring side down) into
recessed machined groove on timing chain cover (Fig. 4).
(3) Position thermostat housing on timing chain
cover.
(4) Install two housing-to-timing chain cover bolts.
Tighten bolts to 13 N´m (115 in. lbs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
(5)
Install lower radiator hose on thermostat housing.
(6) Install splash shield.
(7) Lower vehicle.
(8) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(9) Connect negative battery cable to battery.
(10) Start and warm the engine. Check for leaks.
RADIATOR
DESCRIPTION
All vehicles are equipped with a cross flow type
radiator with plastic side tanks (Fig. 5).Plastic tanks, while stronger than brass, are sub-
ject to damage by impact, such as from tools or
wrenches. Handle radiator with care.
Fig. 4 Thermostat and Thermostat Housing
1 - THERMOSTAT HOUSING
2 - THERMOSTAT LOCATION3 - THERMOSTAT AND GASKET
4 - TIMING CHAIN COVER
Fig. 5 Cross Flow Radiator - Typical
1 - RADIATOR
7 - 22 ENGINEKJ
ENGINE COOLANT THERMOSTAT (Continued)

RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system cap is located on the coolant
pressure bottle. The cap construction includes; stain-
less steel swivel top, rubber seals and retainer, main
spring, and a spring loaded valve (Fig. 10).
OPERATION
The pressure cap allows the cooling system to oper-
ate at higher than atmospheric pressure which raises
the coolant boiling point, thus allowing increased
radiator cooling capacity. The pressure cap releases
pressure at some point within a range of 110 kPa  
14 kPa (16 psi   2 psi).
A spring-loaded vent valve in the center of the cap
allows the system to pressurize and depressurize
without creating a vacuum. If the valve is stuck
open, coolant will escape to the overflow hose. There
is also a gasket in the cap to seal to the top of the
filler neck.
CAUTION: Use only the pressure cap specified for
this vehicle. Use of other pressure caps can lead to
coolant loss and overheating.
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP
Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install the cap on pressure tester (tool 7700 or
an equivalent) (Fig. 11).Operate the tester pump and observe the gauge
pointer at its highest point. The cap release pressure
should be 124 to 145 kPa (18 to 21 psi). The cap is
satisfactory when the pressure holds steady. It is also
good if it holds pressure within the 124 to 145 kPa
(18 to 21 psi) range for 30 seconds or more. If the
pointer drops quickly, replace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Clean the radiator pressure cap using a mild soap
and water only.
INSPECTION
Visually inspect the pressure valve gasket on the
cap. Replace cap if the gasket is swollen, torn or
worn. Inspect the area around radiator filler neck for
white deposits that indicate a leaking cap.
Fig. 10 PRESSURE CAP
1 - MAIN SPRING
2 - GASKET RETAINER
3 - STAINLESS STEEL SWIVEL TOP
4 - RUBBER SEALS
5 - SPRING LOADED VALVE
6 - COOLANT PRESSURE BOTTLE
7 - FILLER NECK
8 - OVERFLOW NIPPLEFig. 11 Pressure Testing Radiator Pressure Cap -
Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
KJENGINE 7 - 25

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)

WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 124 KPA (18 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack in engine. Repair
as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.
If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
7s - 4 COOLING - 2.4LKJ
COOLING - 2.4L (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)

NOTE: The engine cooling system will push any
remaining air into the coolant bottle within about an
hour of normal driving. As a result, a drop in cool-
ant level in the pressure bottle may occur. If the
engine cooling system overheats and pushes cool-
ant into the overflow side of the coolant bottle, this
coolant will be sucked back into the cooling system
ONLY IF THE PRESSURE CAP IS LEFT ON THE
BOTTLE. Removing the pressure cap breaks the
vacuum path between the two bottle sections and
the coolant will not return to cooling system.
(3) With heater control unit in the HEAT position,
operate engine with pressure bottle cap in place.
(4) Add coolant to pressure bottle as necessary.
Only add coolant to the pressure bottle when
the engine is cold. Coolant level in a warm
engine will be higher due to thermal expansion.
NOTE: The coolant bottle has two chambers. Cool-
ant will normally only be in the outboard (larger) of
the two. The inboard chamber is only to recover
coolant in the event of an overheat or after a recent
service fill. The inboard chamber should normally
be empty. If there is coolant in the overflow side of
the coolant bottle (after several warm/cold cycles of
the engine) and coolant level is above cold full
when cold, disconnect the end of the overflow hose
at the fill neck and lower it into a clean container.
Allow coolant to drain into the container until emp-
tied. Reconnect overflow hose to fill neck.
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-110 kPa (14-to -16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse flushing of the cooling system is the forc-
ing of water through the cooling system. This is done
using air pressure in the opposite direction of normal
coolant flow. It is usually only necessary with very
dirty systems with evidence of partial plugging.
CHEMICAL CLEANING
If visual inspection indicates the formation of
sludge or scaly deposits, use a radiator cleaner
(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator
is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
ment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE
Drain the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). Remove the thermostat
housing and thermostat. Install the thermostat hous-
ing. Disconnect the radiator upper hose from the
radiator and attach the flushing gun to the hose. Dis-
connect the radiator lower hose from the water
pump. Attach a lead away hose to the water pump
inlet fitting.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
water. When the engine is filled, apply air in short
blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo-
stat housing (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT - REMOVAL).
Install the thermostat and housing with a replace-
ment gasket (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT -
INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).
7s - 12 COOLING - 2.4LKJ
COOLING - 2.4L (Continued)