brake JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

COOLANT TEMPERATURE SENSOR -
OPERATION, ENGINE...................7-21
COOLANT TEMPERATURE SENSOR -
REMOVAL, ENGINE....................7-21
COOLER - DESCRIPTION, TRANS.........7-30
COOLERS AND TUBES - STANDARD
PROCEDURE, FLUSHING................7-30
COOLING, SPECIAL TOOLS..............7-13
COOLING SYSTEM - OPERATION..........7-2
COOLING SYSTEM - REVERSE
FLUSHING - STANDARD PROCEDURE.....7-12
COOLING SYSTEM - STANDARD
PROCEDURE, DRAINING................7-11
COOLING SYSTEM - STANDARD
PROCEDURE, REFILLING................7-11
COOLING SYSTEM 2.4L ENGINE -
DESCRIPTION.........................7-1
COOLING SYSTEM DIAGNOSIS CHART -
DIAGNOSIS AND TESTING...............7-5
COOLING SYSTEM LEAKS - DIAGNOSIS
AND TESTING.........................7-2
CORE AND OIL GALLERY PLUGS -
STANDARD PROCEDURE, ENGINE.........9-9
COVER - CLEANING, CYLINDER HEAD.....9-26
COVER - INSPECTION, CYLINDER HEAD . . . 9-26
COVER - INSTALLATION, CYLINDER
HEAD...............................9-26
COVER - REMOVAL, CYLINDER HEAD.....9-26
COVER(S) - INSTALLATION, TIMING
BELT ...............................9-53
COVER(S) - REMOVAL, TIMING BELT......9-53
CRANKSHAFT - DESCRIPTION...........9-32
CRANKSHAFT - INSPECTION.............9-34
CRANKSHAFT - INSTALLATION...........9-34
CRANKSHAFT - OPERATION.............9-33
CRANKSHAFT - REMOVAL..............9-33
CRANKSHAFT END PLAY - STANDARD
PROCEDURE.........................9-33
CRANKSHAFT OIL SEAL - FRONT -
INSTALLATION........................9-37
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL...........................9-37
CRANKSHAFT OIL SEAL - REAR -
INSTALLATION........................9-39
CRANKSHAFT OIL SEAL - REAR -
REMOVAL...........................9-38
CRANKSHAFT SPROCKET -
INSTALLATION........................9-56
CRANKSHAFT SPROCKET - REMOVAL.....9-55
CROSS-OVER PIPE - INSTALLATION.......11-4
CROSS-OVER PIPE - REMOVAL..........11-4
CYLINDER BORE FITTING - STANDARD
PROCEDURE, PISTON TO...............9-30
CYLINDER BORE HONING - STANDARD
PROCEDURE.........................9-31
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST - DIAGNOSIS AND
TESTING.............................9-3
CYLINDER COMPRESSION PRESSURE
TEST - DIAGNOSIS AND TESTING.........9-3
CYLINDER HEAD - CLEANING............9-20
CYLINDER HEAD - DESCRIPTION.........9-19
CYLINDER HEAD - INSPECTION..........9-21
CYLINDER HEAD - INSTALLATION........9-21
CYLINDER HEAD - OPERATION...........9-19
CYLINDER HEAD - REMOVAL............9-20
CYLINDER HEAD COVER - CLEANING......9-26
CYLINDER HEAD COVER - INSPECTION....9-26
CYLINDER HEAD COVER -
INSTALLATION
........................9-26
CYLINDER HEAD COVER - REMOVAL
......9-26
CYLINDER HEAD GASKET - DIAGNOSIS
AND TESTING
........................9-19
CYLINDER HEAD OFF - INSTALLATION
.....9-28
CYLINDER HEAD OFF - REMOVAL
........9-27
CYLINDER HEAD ON - INSTALLATION
.....9-28
CYLINDER HEAD ON - REMOVAL
.........9-27
DAMAGED OR WORN THREADS -
STANDARD PROCEDURE, REPAIR OF
.......9-9
DAMPER - INSTALLATION, VIBRATION
.....9-43
DAMPER - REMOVAL, VIBRATION
........9-43
DAYTIME RUNNING LAMP RELAY -
DESCRIPTION
.......................8L-20
DAYTIME RUNNING LAMP RELAY -
INSTALLATION
.......................8L-21
DAYTIME RUNNING LAMP RELAY -
OPERATION
.........................8L-20DAYTIME RUNNING LAMP RELAY -
REMOVAL..........................8L-21
DESCRIPTION - OPERATION.............7-20
DESCRIPTION, BACKUP LAMP SWITCH . . . 8L-15
DESCRIPTION, BALANCE SHAFT..........9-59
DESCRIPTION, BRAKE LAMP SWITCH....8L-16
DESCRIPTION, CAMSHAFT(S)............9-23
DESCRIPTION, CATALYTIC CONVERTER....11-2
DESCRIPTION, COMBINATION FLASHER . . . 8L-19
DESCRIPTION, COOLANT RECOVERY
PRESS CONTAINER....................7-20
DESCRIPTION, COOLING SYSTEM 2.4L
ENGINE..............................7-1
DESCRIPTION, CRANKSHAFT............9-32
DESCRIPTION, CYLINDER HEAD..........9-19
DESCRIPTION, DAYTIME RUNNING
LAMP RELAY........................8L-20
DESCRIPTION, ENGINE - 2.4L.............9-3
DESCRIPTION, ENGINE BLOCK...........9-30
DESCRIPTION, ENGINE BLOCK HEATER -
2.4L................................7-20
DESCRIPTION, ENGINE COOLANT.........7-19
DESCRIPTION, ENGINE COOLANT
TEMPERATURE SENSOR................7-21
DESCRIPTION, ENGINE MOUNTING.......9-44
DESCRIPTION, EXHAUST MANIFOLD......9-53
DESCRIPTION, EXHAUST SYSTEM........11-1
DESCRIPTION, FRONT FOG LAMP RELAY . . 8L-22
DESCRIPTION, HAZARD SWITCH........8L-28
DESCRIPTION, HEADLAMP HIGH BEAM
RELAY.............................8L-33
DESCRIPTION, HEADLAMP LEVELING
MOTOR............................8L-35
DESCRIPTION, HEADLAMP LEVELING
SWITCH............................8L-37
DESCRIPTION, HEADLAMP LOW BEAM
RELAY.............................8L-39
DESCRIPTION, HEAT SHIELDS...........11-4
DESCRIPTION, HOAT COOLANT..........7-18
DESCRIPTION, HOSE CLAMPS............7-1
DESCRIPTION, INTAKE MANIFOLD........9-51
DESCRIPTION, INTAKE/EXHAUST VALVES
& SEATS ............................9-27
DESCRIPTION, LAMP BAR.............8L-65
DESCRIPTION, LAMP BAR SWITCH......8L-67
DESCRIPTION, LAMPS/LIGHTING -
EXTERIOR...........................8L-2
DESCRIPTION, LUBRICATION............9-46
DESCRIPTION, MUFFLER...............11-4
DESCRIPTION, MULTI-FUNCTION
SWITCH............................8L-46
DESCRIPTION, OIL FILTER..............9-47
DESCRIPTION, OIL PRESSURE
SENSOR/SWITCH.....................9-48
DESCRIPTION, PARK LAMP RELAY.......8L-54
DESCRIPTION, PISTON & CONNECTING
ROD................................9-40
DESCRIPTION, RADIATOR...............7-22
DESCRIPTION, RADIATOR FAN -
ELECTRIC...........................7-26
DESCRIPTION, RADIATOR PRESSURE
CAP ................................7-25
DESCRIPTION, REAR FOG LAMP RELAY . . . 8L-56
DESCRIPTION, TRAILER TOW RELAY.....8L-62
DESCRIPTION, TRAILER TOW WIRING....8L-64
DESCRIPTION, TRANS COOLER..........7-30
DESCRIPTION, WATER PUMP - 2.4L......7-27
DIAGNOSIS - DIAGNOSIS AND TESTING,
LASH ADJUSTER (TAPPET) NOISE........9-28
DIAGNOSIS - DIAGNOSIS AND TESTING,
SERPENTINE DRIVE BELT...............7-15
DIAGNOSIS - PERFORMANCE -
DIAGNOSIS AND TESTING, ENGINE........9-5
DIAGNOSIS AND TESTING, BACKUP
LAMP SWITCH......................8L-15
DIAGNOSIS AND TESTING, BRAKE LAMP
SWITCH............................8L-17
DIAGNOSIS AND TESTING, COOLING
SYSTEM DIAGNOSIS CHART
..............7-5
DIAGNOSIS AND TESTING, COOLING
SYSTEM LEAKS
........................7-2
DIAGNOSIS AND TESTING, CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST
................................9-3
DIAGNOSIS AND TESTING, CYLINDER
COMPRESSION PRESSURE TEST
..........9-3
DIAGNOSIS AND TESTING, CYLINDER
HEAD GASKET
........................9-19DIAGNOSIS AND TESTING, ENGINE........9-5
DIAGNOSIS AND TESTING, ENGINE
DIAGNOSIS - PERFORMANCE.............9-5
DIAGNOSIS AND TESTING, ENGINE
MECHANICAL.........................9-7
DIAGNOSIS AND TESTING, ENGINE OIL
LEAK INSPECTION......................9-4
DIAGNOSIS AND TESTING, ENGINE OIL
PRESSURE CHECKING.................9-46
DIAGNOSIS AND TESTING, EXHAUST
SYSTEM............................11-2
DIAGNOSIS AND TESTING, FRONT FOG
LAMP RELAY........................8L-23
DIAGNOSIS AND TESTING, HEADLAMP
HIGH BEAM RELAY...................8L-34
DIAGNOSIS AND TESTING, HEADLAMP
LEVELING SWITCH...................8L-37
DIAGNOSIS AND TESTING, HEADLAMP
LOW BEAM RELAY...................8L-40
DIAGNOSIS AND TESTING, INTAKE
MANIFOLD LEAKS.....................9-51
DIAGNOSIS AND TESTING, LAMP BAR....8L-65
DIAGNOSIS AND TESTING, LAMPS/
LIGHTING - EXTERIOR.................8L-7
DIAGNOSIS AND TESTING, LASH
ADJUSTER (TAPPET) NOISE
DIAGNOSIS..........................9-28
DIAGNOSIS AND TESTING, MULTI-
FUNCTION SWITCH...................8L-50
DIAGNOSIS AND TESTING, ON-BOARD
DIAGNOSTICS (OBD)....................7-2
DIAGNOSIS AND TESTING, PARK LAMP
RELAY.............................8L-55
DIAGNOSIS AND TESTING,
PRELIMINARY CHECKS..................7-2
DIAGNOSIS AND TESTING, RADIATOR
PRESSURE CAP.......................7-25
DIAGNOSIS AND TESTING, REAR FOG
LAMP RELAY........................8L-57
DIAGNOSIS AND TESTING, SERPENTINE
DRIVE BELT DIAGNOSIS................7-15
DIAGNOSIS AND TESTING, TRAILER
TOW RELAY.........................8L-62
DIAGNOSIS CHART - DIAGNOSIS AND
TESTING, COOLING SYSTEM.............7-5
DIAGNOSTICS (OBD) - DIAGNOSIS AND
TESTING, ON-BOARD...................7-2
DISASSEMBLY, OIL PUMP...............9-49
DRAINING COOLING SYSTEM -
STANDARD PROCEDURE................7-11
DRIVE BELT DIAGNOSIS - DIAGNOSIS
AND TESTING, SERPENTINE.............7-15
ELECTRIC - DESCRIPTION, RADIATOR
FAN ................................7-26
ELECTRIC - INSTALLATION, RADIATOR
FAN ................................7-27
ELECTRIC - OPERATION, RADIATOR FAN . . . 7-26
ELECTRIC - REMOVAL, RADIATOR FAN....7-26
END PLAY - STANDARD PROCEDURE,
CRANKSHAFT........................9-33
END-PLAY - STANDARD PROCEDURE,
CAMSHAFT..........................9-23
ENGINE - 2.4L - DESCRIPTION............9-3
ENGINE - DESCRIPTION, COOLING
SYSTEM 2.4L.........................7-1
ENGINE - DIAGNOSIS AND TESTING.......9-5
ENGINE - INSTALLATION, 2.4L . . 7-14,7-17,7-22,
7-28
ENGINE - REMOVAL, 2.4L . . . 7-14,7-16,7-22,7-27
ENGINE - SPECIFICATIONS, 2.4L.........9-13
ENGINE - STANDARD PROCEDURE,
HYDROSTATIC LOCKED..................9-9
ENGINE ASSEMBLY - INSTALLATION......9-12
ENGINE ASSEMBLY - REMOVAL..........9-12
ENGINE BLOCK - DESCRIPTION..........9-30
ENGINE BLOCK HEATER - 2.4L -
DESCRIPTION........................7-20
ENGINE BLOCK HEATER - 2.4L -
OPERATION..........................7-20
ENGINE COOLANT - DESCRIPTION
........7-19
ENGINE COOLANT TEMPERATURE
SENSOR - DESCRIPTION
...............7-21
ENGINE COOLANT TEMPERATURE
SENSOR - INSTALLATION
...............7-22
ENGINE COOLANT TEMPERATURE
SENSOR - OPERATION
.................7-21
ENGINE COOLANT TEMPERATURE
SENSOR - REMOVAL
...................7-21
2 INDEXKJ
Description Group-Page Description Group-Page Description Group-Page

ENGINE CORE AND OIL GALLERY PLUGS
- STANDARD PROCEDURE...............9-9
ENGINE DIAGNOSIS - PERFORMANCE -
DIAGNOSIS AND TESTING...............9-5
ENGINE GASKET SURFACE
PREPARATION - STANDARD
PROCEDURE.........................9-11
ENGINE MECHANICAL - DIAGNOSIS AND
TESTING.............................9-7
ENGINE MOUNTING - DESCRIPTION......9-44
ENGINE OIL AND FILTER CHANGE -
STANDARD PROCEDURE................9-47
ENGINE OIL LEAK INSPECTION -
DIAGNOSIS AND TESTING...............9-4
ENGINE OIL LEVEL CHECK, STANDARD
PROCEDURE.........................9-47
ENGINE OIL PRESSURE CHECKING -
DIAGNOSIS AND TESTING..............9-46
ENGINE, SPECIAL TOOLS - 2.4L..........9-17
EXHAUST MANIFOLD - CLEANING........9-53
EXHAUST MANIFOLD - DESCRIPTION.....9-53
EXHAUST MANIFOLD - INSPECTION.......9-53
EXHAUST MANIFOLD - INSTALLATION.....9-53
EXHAUST MANIFOLD - OPERATION.......9-53
EXHAUST MANIFOLD - REMOVAL.........9-53
EXHAUST SYSTEM - DESCRIPTION.......11-1
EXHAUST SYSTEM - DIAGNOSIS AND
TESTING............................11-2
EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING...........................8L-2
EXTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING.....................8L-7
EXTERIOR - OPERATION, LAMPS/
LIGHTING...........................8L-5
EXTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING....................8L-15
FAN - ELECTRIC - DESCRIPTION,
RADIATOR...........................7-26
FAN - ELECTRIC - INSTALLATION,
RADIATOR...........................7-27
FAN - ELECTRIC - OPERATION,
RADIATOR...........................7-26
FAN - ELECTRIC - REMOVAL, RADIATOR . . . 7-26
FILTER - DESCRIPTION, OIL.............9-47
FILTER - INSTALLATION, OIL............9-47
FILTER - REMOVAL, OIL................9-47
FILTER CHANGE - STANDARD
PROCEDURE, ENGINE OIL...............9-47
FITTING - CONNECTING ROD............9-32
FITTING - PISTON RING................9-42
FITTING - STANDARD PROCEDURE,
MAIN BEARING.......................9-35
FITTING - STANDARD PROCEDURE,
PISTON TO CYLINDER BORE............9-30
FLASHER - DESCRIPTION, COMBINATION . 8L-19
FLASHER - OPERATION, COMBINATION . . . 8L-19
FLUSHING - STANDARD PROCEDURE,
COOLING SYSTEM - REVERSE...........7-12
FLUSHING COOLERS AND TUBES -
STANDARD PROCEDURE................7-30
FOG LAMP BULB - INSTALLATION,
FRONT.............................8L-22
FOG LAMP BULB - REMOVAL, FRONT....8L-21
FOG LAMP RELAY - DESCRIPTION,
FRONT.............................8L-22
FOG LAMP RELAY - DESCRIPTION, REAR . 8L-56
FOG LAMP RELAY - DIAGNOSIS AND
TESTING, FRONT.....................8L-23
FOG LAMP RELAY - DIAGNOSIS AND
TESTING, REAR......................8L-57
FOG LAMP RELAY - INSTALLATION,
FRONT.............................8L-24
FOG LAMP RELAY - INSTALLATION,
REAR..............................8L-58
FOG LAMP RELAY - OPERATION, FRONT . . 8L-22
FOG LAMP RELAY - OPERATION, REAR . . . 8L-57
FOG LAMP RELAY - REMOVAL, FRONT . . . 8L-24
FOG LAMP RELAY - REMOVAL, REAR....8L-58
FOG LAMP UNIT - ADJUSTMENT, FRONT . . 8L-25
FOG LAMP UNIT - INSTALLATION,
FRONT
.............................8L-25
FOG LAMP UNIT - REMOVAL, FRONT
.....8L-24
FORM-IN-PLACE GASKETS AND
SEALERS - STANDARD PROCEDURE
......9-10
FRONT - INSTALLATION, CRANKSHAFT
OIL SEAL
............................9-37
FRONT - REMOVAL, CRANKSHAFT OIL
SEAL
...............................9-37FRONT FOG LAMP BULB -
INSTALLATION.......................8L-22
FRONT FOG LAMP BULB - REMOVAL.....8L-21
FRONT FOG LAMP RELAY -
DESCRIPTION.......................8L-22
FRONT FOG LAMP RELAY - DIAGNOSIS
AND TESTING.......................8L-23
FRONT FOG LAMP RELAY -
INSTALLATION.......................8L-24
FRONT FOG LAMP RELAY - OPERATION . . 8L-22
FRONT FOG LAMP RELAY - REMOVAL....8L-24
FRONT FOG LAMP UNIT - ADJUSTMENT . . 8L-25
FRONT FOG LAMP UNIT - INSTALLATION . . 8L-25
FRONT FOG LAMP UNIT - REMOVAL.....8L-24
FRONT LAMP BULB - INSTALLATION.....8L-27
FRONT LAMP BULB - REMOVAL.........8L-27
FRONT LAMP UNIT - INSTALLATION.....8L-28
FRONT LAMP UNIT - REMOVAL.........8L-27
FRONT MOUNT - INSTALLATION..........9-44
FRONT MOUNT - REMOVAL.............9-44
FRONT POSITION LAMP BULB -
INSTALLATION.......................8L-28
FRONT POSITION LAMP BULB -
REMOVAL..........................8L-28
FRONT SUSPENSION, SPECIAL TOOLS.....2-1
GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE AND OIL......9-9
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD......................9-19
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE........9-11
GASKETS AND SEALERS - STANDARD
PROCEDURE, FORM-IN-PLACE...........9-10
HAZARD SWITCH - DESCRIPTION.......8L-28
HAZARD SWITCH - INSTALLATION.......8L-30
HAZARD SWITCH - OPERATION.........8L-29
HAZARD SWITCH - REMOVAL..........8L-29
HEAD - CLEANING, CYLINDER...........9-20
HEAD - DESCRIPTION, CYLINDER........9-19
HEAD - INSPECTION, CYLINDER..........9-21
HEAD - INSTALLATION, CYLINDER........9-21
HEAD - OPERATION, CYLINDER..........9-19
HEAD - REMOVAL, CYLINDER...........9-20
HEAD COVER - CLEANING, CYLINDER.....9-26
HEAD COVER - INSPECTION, CYLINDER . . . 9-26
HEAD COVER - INSTALLATION,
CYLINDER...........................9-26
HEAD COVER - REMOVAL, CYLINDER.....9-26
HEAD GASKET - DIAGNOSIS AND
TESTING, CYLINDER...................9-19
HEAD OFF - INSTALLATION, CYLINDER....9-28
HEAD OFF - REMOVAL, CYLINDER........9-27
HEAD ON - INSTALLATION, CYLINDER.....9-28
HEAD ON - REMOVAL, CYLINDER........9-27
HEADLAMP BULB - INSTALLATION.......8L-32
HEADLAMP BULB - REMOVAL..........8L-30
HEADLAMP HIGH BEAM RELAY -
DESCRIPTION.......................8L-33
HEADLAMP HIGH BEAM RELAY -
DIAGNOSIS AND TESTING.............8L-34
HEADLAMP HIGH BEAM RELAY -
INSTALLATION.......................8L-35
HEADLAMP HIGH BEAM RELAY -
OPERATION.........................8L-33
HEADLAMP HIGH BEAM RELAY -
REMOVAL..........................8L-34
HEADLAMP LEVELING MOTOR -
DESCRIPTION.......................8L-35
HEADLAMP LEVELING MOTOR -
INSTALLATION.......................8L-36
HEADLAMP LEVELING MOTOR -
OPERATION.........................8L-36
HEADLAMP LEVELING MOTOR -
REMOVAL..........................8L-36
HEADLAMP LEVELING SWITCH -
DESCRIPTION.......................8L-37
HEADLAMP LEVELING SWITCH -
DIAGNOSIS AND TESTING.............8L-37
HEADLAMP LEVELING SWITCH -
INSTALLATION
.......................8L-38
HEADLAMP LEVELING SWITCH -
OPERATION
.........................8L-37
HEADLAMP LEVELING SWITCH -
REMOVAL
..........................8L-38
HEADLAMP LOW BEAM RELAY -
DESCRIPTION
.......................8L-39
HEADLAMP LOW BEAM RELAY -
DIAGNOSIS AND TESTING
.............8L-40HEADLAMP LOW BEAM RELAY -
INSTALLATION.......................8L-41
HEADLAMP LOW BEAM RELAY -
OPERATION.........................8L-39
HEADLAMP LOW BEAM RELAY -
REMOVAL..........................8L-40
HEADLAMP UNIT - ADJUSTMENT........8L-42
HEADLAMP UNIT - INSTALLATION.......8L-42
HEADLAMP UNIT - REMOVAL...........8L-41
HEAT SHIELDS - DESCRIPTION..........11-4
HEATER - 2.4L - DESCRIPTION, ENGINE
BLOCK..............................7-20
HEATER - 2.4L - OPERATION, ENGINE
BLOCK..............................7-20
HIGH BEAM RELAY - DESCRIPTION,
HEADLAMP.........................8L-33
HIGH BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP.................8L-34
HIGH BEAM RELAY - INSTALLATION,
HEADLAMP.........................8L-35
HIGH BEAM RELAY - OPERATION,
HEADLAMP.........................8L-33
HIGH BEAM RELAY - REMOVAL,
HEADLAMP.........................8L-34
HIGH MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER...............8L-19
HIGH MOUNTED STOP LAMP BULB -
REMOVAL, CENTER...................8L-18
HIGH MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER...............8L-19
HIGH MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER...................8L-19
HOAT COOLANT - DESCRIPTION..........7-18
HONING - STANDARD PROCEDURE,
CYLINDER BORE......................9-31
HOSE CLAMPS - DESCRIPTION...........7-1
HOSE CLAMPS - OPERATION.............7-2
HYDRAULIC LIFTERS - INSTALLATION.....9-29
HYDRAULIC LIFTERS - REMOVAL.........9-29
HYDROSTATIC LOCKED ENGINE -
STANDARD PROCEDURE.................9-9
INSPECTION - DIAGNOSIS AND
TESTING, ENGINE OIL LEAK..............9-4
INSPECTION, CAMSHAFT(S).............9-25
INSPECTION, CATALYTIC CONVERTER.....11-3
INSPECTION, CRANKSHAFT.............9-34
INSPECTION, CYLINDER HEAD...........9-21
INSPECTION, CYLINDER HEAD COVER.....9-26
INSPECTION, EXHAUST MANIFOLD.......9-53
INSPECTION, INTAKE MANIFOLD.........9-52
INSPECTION, OIL PUMP................9-50
INSPECTION, RADIATOR................7-24
INSPECTION, RADIATOR PRESSURE CAP . . . 7-25
INSPECTION, REMOVAL................9-28
INSPECTION, ROCKER ARMS............9-30
INSPECTION, STANDARD PROCEDURE.....9-32
INSPECTION, WATER PUMP - 2.4L........7-28
INSTALLATION - BALANCE SHAFT
TIMING.............................9-61
INSTALLATION, 2.4L...................7-20
INSTALLATION, 2.4L...................9-19
INSTALLATION, 2.4L ENGINE....7-14,7-17,7-22,
7-28
INSTALLATION, BALANCE SHAFT
CARRIER............................9-64
INSTALLATION, BALANCE SHAFT CHAIN . . . 9-64
INSTALLATION, BRAKE LAMP SWITCH....8L-18
INSTALLATION, CAMSHAFT OIL SEAL(S) . . . 9-22
INSTALLATION, CAMSHAFT(S)...........9-25
INSTALLATION, CATALYTIC CONVERTER
....11-3
INSTALLATION, CENTER HIGH MOUNTED
STOP LAMP BULB
....................8L-19
INSTALLATION, CENTER HIGH MOUNTED
STOP LAMP UNIT
....................8L-19
INSTALLATION, CLEVIS BRACKET
BUSHING
.............................2-4
INSTALLATION, CRANKSHAFT
............9-34
INSTALLATION, CRANKSHAFT OIL SEAL -
FRONT
..............................9-37
INSTALLATION, CRANKSHAFT OIL SEAL -
REAR
...............................9-39
INSTALLATION, CRANKSHAFT SPROCKET
. . 9-56
INSTALLATION, CROSS-OVER PIPE
.......11-4
INSTALLATION, CYLINDER HEAD
.........9-21
INSTALLATION, CYLINDER HEAD COVER
. . . 9-26
INSTALLATION, CYLINDER HEAD OFF
......9-28
INSTALLATION, CYLINDER HEAD ON
......9-28
KJINDEX 3
Description Group-Page Description Group-Page Description Group-Page

INSTALLATION, DAYTIME RUNNING
LAMP RELAY........................8L-21
INSTALLATION, ENGINE ASSEMBLY.......9-12
INSTALLATION, ENGINE COOLANT
TEMPERATURE SENSOR................7-22
INSTALLATION, EXHAUST MANIFOLD......9-53
INSTALLATION, FRONT FOG LAMP BULB . . 8L-22
INSTALLATION, FRONT FOG LAMP
RELAY.............................8L-24
INSTALLATION, FRONT FOG LAMP UNIT . . 8L-25
INSTALLATION, FRONT LAMP BULB......8L-27
INSTALLATION, FRONT LAMP UNIT......8L-28
INSTALLATION, FRONT MOUNT..........9-44
INSTALLATION, FRONT POSITION LAMP
BULB..............................8L-28
INSTALLATION, HAZARD SWITCH........8L-30
INSTALLATION, HEADLAMP BULB.......8L-32
INSTALLATION, HEADLAMP HIGH BEAM
RELAY.............................8L-35
INSTALLATION, HEADLAMP LEVELING
MOTOR............................8L-36
INSTALLATION, HEADLAMP LEVELING
SWITCH............................8L-38
INSTALLATION, HEADLAMP LOW BEAM
RELAY.............................8L-41
INSTALLATION, HEADLAMP UNIT........8L-42
INSTALLATION, HYDRAULIC LIFTERS......9-29
INSTALLATION, INTAKE MANIFOLD........9-52
INSTALLATION, LAMP.................8L-66
INSTALLATION, LAMP BAR.............8L-66
INSTALLATION, LAMP BAR SWITCH......8L-67
INSTALLATION, LICENSE PLATE LAMP
BULB..............................8L-45
INSTALLATION, LICENSE PLATE LAMP
UNIT..............................8L-46
INSTALLATION, LOWER BALL JOINT.......2-5
INSTALLATION, LOWER CONTROL ARM
BUSHING.............................2-3
INSTALLATION, LOWER SUSPENSION
ARM BUSHING........................2-8
INSTALLATION, MUFFLER...............11-5
INSTALLATION, MULTI-FUNCTION
SWITCH............................8L-53
INSTALLATION, OIL FILTER..............9-47
INSTALLATION, OIL PAN................9-48
INSTALLATION, OIL PUMP..............9-50
INSTALLATION, PARK LAMP RELAY......8L-56
INSTALLATION, PISTON & CONNECTING
ROD................................9-41
INSTALLATION, RADIATOR..............7-24
INSTALLATION, RADIATOR FAN -
ELECTRIC...........................7-27
INSTALLATION, REAR FOG LAMP RELAY . . 8L-58
INSTALLATION, REAR LAMP BULB.......8L-59
INSTALLATION, REAR LAMP UNIT.......8L-60
INSTALLATION, REAR MOUNT...........9-45
INSTALLATION, REPEATER LAMP BULB . . . 8L-60
INSTALLATION, REPEATER LAMP UNIT . . . 8L-61
INSTALLATION, RHD....................5-1
INSTALLATION, ROCKER ARMS..........9-30
INSTALLATION, STRUCTURAL COLLAR....9-44
INSTALLATION, TIMING BELT............9-56
INSTALLATION, TIMING BELT COVER(S) . . . 9-53
INSTALLATION, TIMING BELT
TENSIONER & PULLEY.................9-59
INSTALLATION, TRAILER TOW
CONNECTOR........................8L-61
INSTALLATION, TRAILER TOW RELAY....8L-63
INSTALLATION, UPPER BALL JOINT........2-6
INSTALLATION, UPPER CONTROL ARM
BUSHINGS............................2-4
INSTALLATION, UPPER SUSPENSION
ARM BUSHING........................2-8
INSTALLATION, VIBRATION DAMPER......9-43
INTAKE MANIFOLD - DESCRIPTION.......9-51
INTAKE MANIFOLD - INSPECTION........9-52
INTAKE MANIFOLD - INSTALLATION.......9-52
INTAKE MANIFOLD - OPERATION.........9-51
INTAKE MANIFOLD - REMOVAL..........9-52
INTAKE MANIFOLD LEAKS - DIAGNOSIS
AND TESTING........................9-51
INTAKE/EXHAUST VALVES & SEATS -
CLEANING
...........................9-27
INTAKE/EXHAUST VALVES & SEATS -
DESCRIPTION
........................9-27
JOINT - INSTALLATION, LOWER BALL
......2-5
JOINT - INSTALLATION, UPPER BALL
......2-6
JOINT - REMOVAL, LOWER BALL
..........2-5JOINT - REMOVAL, UPPER BALL..........2-6
LAMP - INSTALLATION................8L-66
LAMP - REMOVAL....................8L-66
LAMP BAR - DESCRIPTION.............8L-65
LAMP BAR - DIAGNOSIS AND TESTING . . . 8L-65
LAMP BAR - INSTALLATION............8L-66
LAMP BAR - OPERATION..............8L-65
LAMP BAR - REMOVAL................8L-65
LAMP BAR AIMING - STANDARD
PROCEDURE........................8L-65
LAMP BAR SWITCH - DESCRIPTION.....8L-67
LAMP BAR SWITCH - INSTALLATION.....8L-67
LAMP BAR SWITCH - REMOVAL.........8L-67
LAMP BULB - INSTALLATION, CENTER
HIGH MOUNTED STOP................8L-19
LAMP BULB - INSTALLATION, FRONT....8L-27
LAMP BULB - INSTALLATION, FRONT
FOG ...............................8L-22
LAMP BULB - INSTALLATION, FRONT
POSITION..........................8L-28
LAMP BULB - INSTALLATION, LICENSE
PLATE .............................8L-45
LAMP BULB - INSTALLATION, REAR.....8L-59
LAMP BULB - INSTALLATION, REPEATER . . 8L-60
LAMP BULB - REMOVAL, CENTER HIGH
MOUNTED STOP.....................8L-18
LAMP BULB - REMOVAL, FRONT........8L-27
LAMP BULB - REMOVAL, FRONT FOG....8L-21
LAMP BULB - REMOVAL, FRONT
POSITION..........................8L-28
LAMP BULB - REMOVAL, LICENSE
PLATE .............................8L-44
LAMP BULB - REMOVAL, REAR.........8L-59
LAMP BULB - REMOVAL, REPEATER.....8L-60
LAMP RELAY - DESCRIPTION, DAYTIME
RUNNING...........................8L-20
LAMP RELAY - DESCRIPTION, FRONT
FOG ...............................8L-22
LAMP RELAY - DESCRIPTION, PARK.....8L-54
LAMP RELAY - DESCRIPTION, REAR FOG . 8L-56
LAMP RELAY - DIAGNOSIS AND
TESTING, FRONT FOG.................8L-23
LAMP RELAY - DIAGNOSIS AND
TESTING, PARK......................8L-55
LAMP RELAY - DIAGNOSIS AND
TESTING, REAR FOG..................8L-57
LAMP RELAY - INSTALLATION, DAYTIME
RUNNING...........................8L-21
LAMP RELAY - INSTALLATION, FRONT
FOG ...............................8L-24
LAMP RELAY - INSTALLATION, PARK.....8L-56
LAMP RELAY - INSTALLATION, REAR
FOG ...............................8L-58
LAMP RELAY - OPERATION, DAYTIME
RUNNING...........................8L-20
LAMP RELAY - OPERATION, FRONT FOG . . 8L-22
LAMP RELAY - OPERATION, PARK.......8L-54
LAMP RELAY - OPERATION, REAR FOG . . . 8L-57
LAMP RELAY - REMOVAL, DAYTIME
RUNNING...........................8L-21
LAMP RELAY - REMOVAL, FRONT FOG . . . 8L-24
LAMP RELAY - REMOVAL, PARK........8L-55
LAMP RELAY - REMOVAL, REAR FOG....8L-58
LAMP SWITCH - DESCRIPTION, BACKUP . . 8L-15
LAMP SWITCH - DESCRIPTION, BRAKE . . . 8L-16
LAMP SWITCH - DIAGNOSIS AND
TESTING, BACKUP....................8L-15
LAMP SWITCH - DIAGNOSIS AND
TESTING, BRAKE.....................8L-17
LAMP SWITCH - INSTALLATION, BRAKE . . 8L-18
LAMP SWITCH - OPERATION, BACKUP . . . 8L-15
LAMP SWITCH - OPERATION, BRAKE.....8L-16
LAMP SWITCH - REMOVAL, BRAKE......8L-17
LAMP UNIT - ADJUSTMENT, FRONT FOG . . 8L-25
LAMP UNIT - INSTALLATION, CENTER
HIGH MOUNTED STOP................8L-19
LAMP UNIT - INSTALLATION, FRONT.....8L-28
LAMP UNIT - INSTALLATION, FRONT
FOG ...............................8L-25
LAMP UNIT - INSTALLATION, LICENSE
PLATE .............................8L-46
LAMP UNIT - INSTALLATION, REAR......8L-60
LAMP UNIT - INSTALLATION, REPEATER
. . 8L-61
LAMP UNIT - REMOVAL, CENTER HIGH
MOUNTED STOP
.....................8L-19
LAMP UNIT - REMOVAL, FRONT
.........8L-27
LAMP UNIT - REMOVAL, FRONT FOG
.....8L-24
LAMP UNIT - REMOVAL, LICENSE PLATE
. . 8L-45LAMP UNIT - REMOVAL, REAR..........8L-59
LAMP UNIT - REMOVAL, REPEATER......8L-61
LAMPS/LIGHTING - EXTERIOR -
DESCRIPTION........................8L-2
LAMPS/LIGHTING - EXTERIOR -
DIAGNOSIS AND TESTING..............8L-7
LAMPS/LIGHTING - EXTERIOR -
OPERATION..........................8L-5
LAMPS/LIGHTING - EXTERIOR -
SPECIFICATIONS.....................8L-15
LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS - DIAGNOSIS AND
TESTING............................9-28
LEAK INSPECTION - DIAGNOSIS AND
TESTING, ENGINE OIL...................9-4
LEAKAGE TEST - DIAGNOSIS AND
TESTING, CYLINDER COMBUSTION
PRESSURE...........................9-3
LEAKS - DIAGNOSIS AND TESTING,
COOLING SYSTEM.....................7-2
LEAKS - DIAGNOSIS AND TESTING,
INTAKE MANIFOLD....................9-51
LEVEL CHECK, STANDARD PROCEDURE
- ENGINE OIL........................9-47
LEVELING MOTOR - DESCRIPTION,
HEADLAMP.........................8L-35
LEVELING MOTOR - INSTALLATION,
HEADLAMP.........................8L-36
LEVELING MOTOR - OPERATION,
HEADLAMP.........................8L-36
LEVELING MOTOR - REMOVAL,
HEADLAMP.........................8L-36
LEVELING SWITCH - DESCRIPTION,
HEADLAMP...........................8L-37
LEVELING SWITCH - DIAGNOSIS AND
TESTING, HEADLAMP.................8L-37
LEVELING SWITCH - INSTALLATION,
HEADLAMP.........................8L-38
LEVELING SWITCH - OPERATION,
HEADLAMP.........................8L-37
LEVELING SWITCH - REMOVAL,
HEADLAMP.........................8L-38
LICENSE PLATE LAMP BULB -
INSTALLATION.......................8L-45
LICENSE PLATE LAMP BULB - REMOVAL . . 8L-44
LICENSE PLATE LAMP UNIT -
INSTALLATION.......................8L-46
LICENSE PLATE LAMP UNIT - REMOVAL . . 8L-45
LIFTERS - INSTALLATION, HYDRAULIC....9-29
LIFTERS - REMOVAL, HYDRAULIC........9-29
LOCKED ENGINE - STANDARD
PROCEDURE, HYDROSTATIC..............9-9
LOW BEAM RELAY - DESCRIPTION,
HEADLAMP.........................8L-39
LOW BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP.................8L-40
LOW BEAM RELAY - INSTALLATION,
HEADLAMP.........................8L-41
LOW BEAM RELAY - OPERATION,
HEADLAMP.........................8L-39
LOW BEAM RELAY - REMOVAL,
HEADLAMP.........................8L-40
LOWER BALL JOINT - INSTALLATION......2-5
LOWER BALL JOINT - REMOVAL..........2-5
LOWER CONTROL ARM BUSHING -
INSTALLATION.........................2-3
LOWER CONTROL ARM BUSHING -
REMOVAL............................2-2
LOWER SUSPENSION ARM BUSHING -
INSTALLATION.........................2-8
LOWER SUSPENSION ARM BUSHING -
REMOVAL............................2-7
LUBRICATION - DESCRIPTION...........9-46
LUBRICATION - OPERATION
.............9-46
MAIN BEARING - FITTING - STANDARD
PROCEDURE
.........................9-35
MANIFOLD - CLEANING, EXHAUST
........9-53
MANIFOLD - DESCRIPTION, EXHAUST
.....9-53
MANIFOLD - DESCRIPTION, INTAKE
.......9-51
MANIFOLD - INSPECTION, EXHAUST
......9-53
MANIFOLD - INSPECTION, INTAKE
........9-52
MANIFOLD - INSTALLATION, EXHAUST
....9-53
MANIFOLD - INSTALLATION, INTAKE
......9-52
MANIFOLD - OPERATION, EXHAUST
.......9-53
MANIFOLD - OPERATION, INTAKE
........9-51
MANIFOLD - REMOVAL, EXHAUST
........9-53
MANIFOLD - REMOVAL, INTAKE
..........9-52
4 INDEXKJ
Description Group-Page Description Group-Page Description Group-Page

MANIFOLD LEAKS - DIAGNOSIS AND
TESTING, INTAKE.....................9-51
MEASURING BEARING CLEARANCE
USING PLASTIGAGE - STANDARD
PROCEDURE.........................9-11
MECHANICAL - DIAGNOSIS AND
TESTING, ENGINE......................9-7
MOTOR - DESCRIPTION, HEADLAMP
LEVELING..........................8L-35
MOTOR - INSTALLATION, HEADLAMP
LEVELING..........................8L-36
MOTOR - OPERATION, HEADLAMP
LEVELING..........................8L-36
MOTOR - REMOVAL, HEADLAMP
LEVELING..........................8L-36
MOUNT - INSTALLATION, FRONT.........9-44
MOUNT - INSTALLATION, REAR..........9-45
MOUNT - REMOVAL, FRONT.............9-44
MOUNT - REMOVAL, REAR..............9-45
MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER HIGH..........8L-19
MOUNTED STOP LAMP BULB -
REMOVAL, CENTER HIGH..............8L-18
MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER HIGH..........8L-19
MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER HIGH..............8L-19
MOUNTING - DESCRIPTION, ENGINE......9-44
MUFFLER - DESCRIPTION...............11-4
MUFFLER - INSTALLATION..............11-5
MUFFLER - REMOVAL..................11-4
MULTI-FUNCTION SWITCH -
DESCRIPTION.......................8L-46
MULTI-FUNCTION SWITCH - DIAGNOSIS
AND TESTING.......................8L-50
MULTI-FUNCTION SWITCH -
INSTALLATION.......................8L-53
MULTI-FUNCTION SWITCH - OPERATION . . 8L-48
MULTI-FUNCTION SWITCH - REMOVAL . . . 8L-53
NOISE DIAGNOSIS - DIAGNOSIS AND
TESTING, LASH ADJUSTER (TAPPET)......9-28
OFF - INSTALLATION, CYLINDER HEAD....9-28
OFF - REMOVAL, CYLINDER HEAD........9-27
OIL AND FILTER CHANGE - STANDARD
PROCEDURE, ENGINE..................9-47
OIL FILTER - DESCRIPTION.............9-47
OIL FILTER - INSTALLATION.............9-47
OIL FILTER - REMOVAL.................9-47
OIL GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE..............9-9
OIL LEAK INSPECTION - DIAGNOSIS
AND TESTING, ENGINE..................9-4
OIL LEVEL CHECK, STANDARD
PROCEDURE - ENGINE.................9-47
OIL PAN - INSTALLATION...............9-48
OIL PAN - REMOVAL...................9-48
OIL PRESSURE CHECKING - DIAGNOSIS
AND TESTING, ENGINE.................9-46
OIL PRESSURE SENSOR/SWITCH -
DESCRIPTION........................9-48
OIL PRESSURE SENSOR/SWITCH -
OPERATION..........................9-48
OIL PUMP - ASSEMBLY................9-50
OIL PUMP - CLEANING.................9-49
OIL PUMP - DISASSEMBLY.............9-49
OIL PUMP - INSPECTION...............9-50
OIL PUMP - INSTALLATION.............9-50
OIL PUMP - REMOVAL.................9-49
OIL SEAL - FRONT - INSTALLATION,
CRANKSHAFT........................9-37
OIL SEAL - FRONT - REMOVAL,
CRANKSHAFT........................9-37
OIL SEAL - REAR - INSTALLATION,
CRANKSHAFT........................9-39
OIL SEAL - REAR - REMOVAL,
CRANKSHAFT........................9-38
OIL SEAL(S) - INSTALLATION,
CAMSHAFT..........................9-22
OIL SEAL(S) - REMOVAL, CAMSHAFT.....9-22
ON-BOARD DIAGNOSTICS (OBD) -
DIAGNOSIS AND TESTING...............7-2
OPERATION, BACKUP LAMP SWITCH.....8L-15
OPERATION, BALANCE SHAFT
...........9-59
OPERATION, BRAKE LAMP SWITCH
......8L-16
OPERATION, CAMSHAFT(S)
.............9-23
OPERATION, COMBINATION FLASHER
....8L-19
OPERATION, COOLANT RECOVERY
PRESS CONTAINER
....................7-20OPERATION, COOLING SYSTEM...........7-2
OPERATION, CRANKSHAFT..............9-33
OPERATION, CYLINDER HEAD...........9-19
OPERATION, DAYTIME RUNNING LAMP
RELAY.............................8L-20
OPERATION, DESCRIPTION..............7-20
OPERATION, ENGINE BLOCK HEATER -
2.4L................................7-20
OPERATION, ENGINE COOLANT
TEMPERATURE SENSOR................7-21
OPERATION, EXHAUST MANIFOLD........9-53
OPERATION, FRONT FOG LAMP RELAY . . . 8L-22
OPERATION, HAZARD SWITCH..........8L-29
OPERATION, HEADLAMP HIGH BEAM
RELAY.............................8L-33
OPERATION, HEADLAMP LEVELING
MOTOR............................8L-36
OPERATION, HEADLAMP LEVELING
SWITCH............................8L-37
OPERATION, HEADLAMP LOW BEAM
RELAY.............................8L-39
OPERATION, HOSE CLAMPS..............7-2
OPERATION, INTAKE MANIFOLD..........9-51
OPERATION, LAMP BAR...............8L-65
OPERATION, LAMPS/LIGHTING -
EXTERIOR...........................8L-5
OPERATION, LUBRICATION..............9-46
OPERATION, MULTI-FUNCTION SWITCH . . . 8L-48
OPERATION, OIL PRESSURE SENSOR/
SWITCH..............................9-48
OPERATION, PARK LAMP RELAY........8L-54
OPERATION, PISTON & CONNECTING
ROD................................9-40
OPERATION, RADIATOR FAN - ELECTRIC . . . 7-26
OPERATION, RADIATOR PRESSURE CAP . . . 7-25
OPERATION, REAR FOG LAMP RELAY....8L-57
OPERATION, TRAILER TOW RELAY.......8L-62
OPERATION, WATER PUMP - 2.4L........7-27
PAN - INSTALLATION, OIL...............9-48
PAN - REMOVAL, OIL..................9-48
PARK LAMP RELAY - DESCRIPTION......8L-54
PARK LAMP RELAY - DIAGNOSIS AND
TESTING...........................8L-55
PARK LAMP RELAY - INSTALLATION.....8L-56
PARK LAMP RELAY - OPERATION.......8L-54
PARK LAMP RELAY - REMOVAL.........8L-55
PERFORMANCE - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS............9-5
PIPE - INSTALLATION, CROSS-OVER......11-4
PIPE - REMOVAL, CROSS-OVER..........11-4
PISTON & CONNECTING ROD -
DESCRIPTION........................9-40
PISTON & CONNECTING ROD -
INSTALLATION........................9-41
PISTON & CONNECTING ROD -
OPERATION..........................9-40
PISTON & CONNECTING ROD -
REMOVAL...........................9-40
PISTON RING, FITTING.................9-42
PISTON TO CYLINDER BORE FITTING -
STANDARD PROCEDURE................9-30
PLASTIGAGE - STANDARD PROCEDURE,
MEASURING BEARING CLEARANCE
USING..............................9-11
PLATE LAMP BULB - INSTALLATION,
LICENSE...........................8L-45
PLATE LAMP BULB - REMOVAL,
LICENSE...........................8L-44
PLATE LAMP UNIT - INSTALLATION,
LICENSE...........................8L-46
PLATE LAMP UNIT - REMOVAL, LICENSE . . 8L-45
PLAY - STANDARD PROCEDURE,
CRANKSHAFT END....................9-33
PLUGS - STANDARD PROCEDURE,
ENGINE CORE AND OIL GALLERY.........9-9
POSITION LAMP BULB - INSTALLATION,
FRONT.............................8L-28
POSITION LAMP BULB - REMOVAL,
FRONT
.............................8L-28
PRELIMINARY CHECKS - DIAGNOSIS
AND TESTING
.........................7-2
PREPARATION - STANDARD
PROCEDURE, ENGINE GASKET
SURFACE
............................9-11
PRESS CONTAINER - DESCRIPTION,
COOLANT RECOVERY
..................7-20
PRESS CONTAINER - OPERATION,
COOLANT RECOVERY
..................7-20PRESSURE CAP - CLEANING, RADIATOR . . . 7-25
PRESSURE CAP - DESCRIPTION,
RADIATOR...........................7-25
PRESSURE CAP - DIAGNOSIS AND
TESTING, RADIATOR...................7-25
PRESSURE CAP - INSPECTION,
RADIATOR...........................7-25
PRESSURE CAP - OPERATION,
RADIATOR...........................7-25
PRESSURE CHECKING - DIAGNOSIS AND
TESTING, ENGINE OIL..................9-46
PRESSURE LEAKAGE TEST - DIAGNOSIS
AND TESTING, CYLINDER
COMBUSTION.........................9-3
PRESSURE SENSOR/SWITCH -
DESCRIPTION, OIL....................9-48
PRESSURE SENSOR/SWITCH -
OPERATION, OIL......................9-48
PRESSURE TEST - DIAGNOSIS AND
TESTING, CYLINDER COMPRESSION.......9-3
PULLEY - INSTALLATION, TIMING BELT
TENSIONER..........................9-59
PULLEY - REMOVAL, TIMING BELT
TENSIONER..........................9-59
PUMP - 2.4L - DESCRIPTION, WATER.....7-27
PUMP - 2.4L - INSPECTION, WATER......7-28
PUMP - 2.4L - OPERATION, WATER.......7-27
PUMP - ASSEMBLY, OIL................9-50
PUMP - CLEANING, OIL................9-49
PUMP - DISASSEMBLY, OIL.............9-49
PUMP - INSPECTION, OIL...............9-50
PUMP - INSTALLATION, OIL.............9-50
PUMP - REMOVAL, OIL.................9-49
RADIATOR - CLEANING.................7-24
RADIATOR - DESCRIPTION..............7-22
RADIATOR - INSPECTION...............7-24
RADIATOR - INSTALLATION.............7-24
RADIATOR - REMOVAL.................7-22
RADIATOR FAN - ELECTRIC -
DESCRIPTION........................7-26
RADIATOR FAN - ELECTRIC -
INSTALLATION........................7-27
RADIATOR FAN - ELECTRIC -
OPERATION..........................7-26
RADIATOR FAN - ELECTRIC - REMOVAL . . . 7-26
RADIATOR PRESSURE CAP - CLEANING . . . 7-25
RADIATOR PRESSURE CAP -
DESCRIPTION........................7-25
RADIATOR PRESSURE CAP - DIAGNOSIS
AND TESTING........................7-25
RADIATOR PRESSURE CAP -
INSPECTION.........................7-25
RADIATOR PRESSURE CAP - OPERATION . . 7-25
REAR - INSTALLATION, CRANKSHAFT
OIL SEAL............................9-39
REAR - REMOVAL, CRANKSHAFT OIL
SEAL...............................9-38
REAR FOG LAMP RELAY - DESCRIPTION . . 8L-56
REAR FOG LAMP RELAY - DIAGNOSIS
AND TESTING.......................8L-57
REAR FOG LAMP RELAY -
INSTALLATION.......................8L-58
REAR FOG LAMP RELAY - OPERATION . . . 8L-57
REAR FOG LAMP RELAY - REMOVAL.....8L-58
REAR LAMP BULB - INSTALLATION......8L-59
REAR LAMP BULB - REMOVAL..........8L-59
REAR LAMP UNIT - INSTALLATION......8L-60
REAR LAMP UNIT - REMOVAL..........8L-59
REAR MOUNT - INSTALLATION..........9-45
REAR MOUNT - REMOVAL..............9-45
REAR SUSPENSION, SPECIAL TOOLS......2-6
RECOVERY PRESS CONTAINER -
DESCRIPTION, COOLANT...............7-20
RECOVERY PRESS CONTAINER -
OPERATION, COOLANT.................7-20
REFILLING COOLING SYSTEM -
STANDARD PROCEDURE................7-11
RELAY - DESCRIPTION, DAYTIME
RUNNING LAMP.....................8L-20
RELAY - DESCRIPTION, FRONT FOG
LAMP..............................8L-22
RELAY - DESCRIPTION, HEADLAMP
HIGH BEAM
.........................8L-33
RELAY - DESCRIPTION, HEADLAMP LOW
BEAM
..............................8L-39
RELAY - DESCRIPTION, PARK LAMP
.....8L-54
RELAY - DESCRIPTION, REAR FOG LAMP
. 8L-56
RELAY - DESCRIPTION, TRAILER TOW
....8L-62
KJINDEX 5
Description Group-Page Description Group-Page Description Group-Page

RELAY - DIAGNOSIS AND TESTING,
FRONT FOG LAMP....................8L-23
RELAY - DIAGNOSIS AND TESTING,
HEADLAMP HIGH BEAM...............8L-34
RELAY - DIAGNOSIS AND TESTING,
HEADLAMP LOW BEAM...............8L-40
RELAY - DIAGNOSIS AND TESTING,
PARK LAMP.........................8L-55
RELAY - DIAGNOSIS AND TESTING,
REAR FOG LAMP.....................8L-57
RELAY - DIAGNOSIS AND TESTING,
TRAILER TOW.......................8L-62
RELAY - INSTALLATION, DAYTIME
RUNNING LAMP.....................8L-21
RELAY - INSTALLATION, FRONT FOG
LAMP..............................8L-24
RELAY - INSTALLATION, HEADLAMP
HIGH BEAM.........................8L-35
RELAY - INSTALLATION, HEADLAMP
LOW BEAM.........................8L-41
RELAY - INSTALLATION, PARK LAMP.....8L-56
RELAY - INSTALLATION, REAR FOG
LAMP..............................8L-58
RELAY - INSTALLATION, TRAILER TOW . . . 8L-63
RELAY - OPERATION, DAYTIME
RUNNING LAMP.....................8L-20
RELAY - OPERATION, FRONT FOG LAMP . . 8L-22
RELAY - OPERATION, HEADLAMP HIGH
BEAM..............................8L-33
RELAY - OPERATION, HEADLAMP LOW
BEAM..............................8L-39
RELAY - OPERATION, PARK LAMP.......8L-54
RELAY - OPERATION, REAR FOG LAMP . . . 8L-57
RELAY - OPERATION, TRAILER TOW.....8L-62
RELAY - REMOVAL, DAYTIME RUNNING
LAMP..............................8L-21
RELAY - REMOVAL, FRONT FOG LAMP . . . 8L-24
RELAY - REMOVAL, HEADLAMP HIGH
BEAM..............................8L-34
RELAY - REMOVAL, HEADLAMP LOW
BEAM..............................8L-40
RELAY - REMOVAL, PARK LAMP........8L-55
RELAY - REMOVAL, REAR FOG LAMP....8L-58
RELAY - REMOVAL, TRAILER TOW.......8L-63
REMOVAL - CLEANING.................9-55
REMOVAL - INSPECTION...............9-28
REMOVAL, 2.4L.......................7-20
REMOVAL, 2.4L.......................9-19
REMOVAL, 2.4L ENGINE....7-14,7-16,7-22,7-27
REMOVAL, BALANCE SHAFT.............9-60
REMOVAL, BALANCE SHAFT CARRIER.....9-64
REMOVAL, BALANCE SHAFT CHAIN.......9-64
REMOVAL, BRAKE LAMP SWITCH.......8L-17
REMOVAL, CAMSHAFT OIL SEAL(S).......9-22
REMOVAL, CAMSHAFT(S)...............9-24
REMOVAL, CATALYTIC CONVERTER.......11-2
REMOVAL, CENTER HIGH MOUNTED
STOP LAMP BULB....................8L-18
REMOVAL, CENTER HIGH MOUNTED
STOP LAMP UNIT....................8L-19
REMOVAL, CLEVIS BRACKET BUSHING.....2-2
REMOVAL, CRANKSHAFT...............9-33
REMOVAL, CRANKSHAFT OIL SEAL -
FRONT..............................9-37
REMOVAL, CRANKSHAFT OIL SEAL -
REAR...............................9-38
REMOVAL, CRANKSHAFT SPROCKET......9-55
REMOVAL, CROSS-OVER PIPE...........11-4
REMOVAL, CYLINDER HEAD.............9-20
REMOVAL, CYLINDER HEAD COVER.......9-26
REMOVAL, CYLINDER HEAD OFF.........9-27
REMOVAL, CYLINDER HEAD ON..........9-27
REMOVAL, DAYTIME RUNNING LAMP
RELAY.............................8L-21
REMOVAL, ENGINE ASSEMBLY...........9-12
REMOVAL, ENGINE COOLANT
TEMPERATURE SENSOR................7-21
REMOVAL, EXHAUST MANIFOLD.........9-53
REMOVAL, FRONT FOG LAMP BULB......8L-21
REMOVAL, FRONT FOG LAMP RELAY.....8L-24
REMOVAL, FRONT FOG LAMP UNIT......8L-24
REMOVAL, FRONT LAMP BULB.........8L-27
REMOVAL, FRONT LAMP UNIT
..........8L-27
REMOVAL, FRONT MOUNT
..............9-44
REMOVAL, FRONT POSITION LAMP
BULB
..............................8L-28
REMOVAL, HAZARD SWITCH
...........8L-29
REMOVAL, HEADLAMP BULB
...........8L-30REMOVAL, HEADLAMP HIGH BEAM
RELAY.............................8L-34
REMOVAL, HEADLAMP LEVELING
MOTOR............................8L-36
REMOVAL, HEADLAMP LEVELING
SWITCH............................8L-38
REMOVAL, HEADLAMP LOW BEAM
RELAY.............................8L-40
REMOVAL, HEADLAMP UNIT...........8L-41
REMOVAL, HYDRAULIC LIFTERS.........9-29
REMOVAL, INTAKE MANIFOLD...........9-52
REMOVAL, LAMP....................8L-66
REMOVAL, LAMP BAR................8L-65
REMOVAL, LAMP BAR SWITCH.........8L-67
REMOVAL, LICENSE PLATE LAMP BULB . . 8L-44
REMOVAL, LICENSE PLATE LAMP UNIT . . . 8L-45
REMOVAL, LOWER BALL JOINT...........2-5
REMOVAL, LOWER CONTROL ARM
BUSHING.............................2-2
REMOVAL, LOWER SUSPENSION ARM
BUSHING.............................2-7
REMOVAL, MUFFLER...................11-4
REMOVAL, MULTI-FUNCTION SWITCH....8L-53
REMOVAL, OIL FILTER.................9-47
REMOVAL, OIL PAN...................9-48
REMOVAL, OIL PUMP..................9-49
REMOVAL, PARK LAMP RELAY..........8L-55
REMOVAL, PISTON & CONNECTING ROD . . . 9-40
REMOVAL, RADIATOR..................7-22
REMOVAL, RADIATOR FAN - ELECTRIC....7-26
REMOVAL, REAR FOG LAMP RELAY......8L-58
REMOVAL, REAR LAMP BULB..........8L-59
REMOVAL, REAR LAMP UNIT...........8L-59
REMOVAL, REAR MOUNT...............9-45
REMOVAL, REPEATER LAMP BULB.......8L-60
REMOVAL, REPEATER LAMP UNIT.......8L-61
REMOVAL, RHD........................5-1
REMOVAL, ROCKER ARMS..............9-29
REMOVAL, STRUCTURAL COLLAR........9-44
REMOVAL, TIMING BELT................9-55
REMOVAL, TIMING BELT COVER(S).......9-53
REMOVAL, TIMING BELT TENSIONER &
PULLEY.............................9-59
REMOVAL, TRAILER TOW CONNECTOR . . . 8L-61
REMOVAL, TRAILER TOW RELAY........8L-63
REMOVAL, UPPER BALL JOINT...........2-6
REMOVAL, UPPER CONTROL ARM
BUSHINGS............................2-3
REMOVAL, UPPER SUSPENSION ARM
BUSHING.............................2-7
REMOVAL, VIBRATION DAMPER..........9-43
REPAIR OF DAMAGED OR WORN
THREADS - STANDARD PROCEDURE.......9-9
REPEATER LAMP BULB - INSTALLATION . . 8L-60
REPEATER LAMP BULB - REMOVAL......8L-60
REPEATER LAMP UNIT - INSTALLATION . . 8L-61
REPEATER LAMP UNIT - REMOVAL......8L-61
REVERSE FLUSHING - STANDARD
PROCEDURE, COOLING SYSTEM.........7-12
RHD - INSTALLATION...................5-1
RHD - REMOVAL.......................5-1
RING, FITTING - PISTON................9-42
ROCKER ARMS - INSPECTION...........9-30
ROCKER ARMS - INSTALLATION.........9-30
ROCKER ARMS - REMOVAL.............9-29
ROD - DESCRIPTION, PISTON &
CONNECTING.........................9-40
ROD - INSTALLATION, PISTON &
CONNECTING.........................9-41
ROD - OPERATION, PISTON &
CONNECTING.........................9-40
ROD - REMOVAL, PISTON &
CONNECTING.........................9-40
ROD, FITTING - CONNECTING............9-32
RUNNING LAMP RELAY - DESCRIPTION,
DAYTIME...........................8L-20
RUNNING LAMP RELAY - INSTALLATION,
DAYTIME...........................8L-21
RUNNING LAMP RELAY - OPERATION,
DAYTIME
...........................8L-20
RUNNING LAMP RELAY - REMOVAL,
DAYTIME
...........................8L-21
SEAL - FRONT - INSTALLATION,
CRANKSHAFT OIL
.....................9-37
SEAL - FRONT - REMOVAL,
CRANKSHAFT OIL
.....................9-37
SEAL - REAR - INSTALLATION,
CRANKSHAFT OIL
.....................9-39SEAL - REAR - REMOVAL, CRANKSHAFT
OIL ................................9-38
SEALERS - STANDARD PROCEDURE,
FORM-IN-PLACE GASKETS..............9-10
SEAL(S) - INSTALLATION, CAMSHAFT
OIL ................................9-22
SEAL(S) - REMOVAL, CAMSHAFT OIL.....9-22
SEATS - CLEANING, INTAKE/EXHAUST
VALVES .............................9-27
SEATS - DESCRIPTION, INTAKE/
EXHAUST VALVES.....................9-27
SENSOR - DESCRIPTION, ENGINE
COOLANT TEMPERATURE...............7-21
SENSOR - INSTALLATION, ENGINE
COOLANT TEMPERATURE...............7-22
SENSOR - OPERATION, ENGINE
COOLANT TEMPERATURE...............7-21
SENSOR - REMOVAL, ENGINE COOLANT
TEMPERATURE.......................7-21
SENSOR/SWITCH - DESCRIPTION, OIL
PRESSURE..........................9-48
SENSOR/SWITCH - OPERATION, OIL
PRESSURE..........................9-48
SERPENTINE DRIVE BELT DIAGNOSIS -
DIAGNOSIS AND TESTING..............7-15
SHAFT - DESCRIPTION, BALANCE........9-59
SHAFT - OPERATION, BALANCE..........9-59
SHAFT - REMOVAL, BALANCE...........9-60
SHAFT CARRIER - INSTALLATION,
BALANCE............................9-64
SHAFT CARRIER - REMOVAL, BALANCE....9-64
SHAFT CHAIN - INSTALLATION,
BALANCE............................9-64
SHAFT CHAIN - REMOVAL, BALANCE......9-64
SHAFT TIMING, INSTALLATION -
BALANCE............................9-61
SHIELDS - DESCRIPTION, HEAT..........11-4
SPECIAL TOOLS - 2.4L ENGINE..........9-17
SPECIAL TOOLS - COOLING.............7-13
SPECIAL TOOLS - FRONT SUSPENSION.....2-1
SPECIAL TOOLS - REAR SUSPENSION......2-6
SPECIFICATIONS - TORQUE.............7-13
SPECIFICATIONS, 2.4L ENGINE...........9-13
SPECIFICATIONS, LAMPS/LIGHTING -
EXTERIOR..........................8L-15
SPECIFICATIONS, TORQUE..............9-16
SPROCKET - INSTALLATION,
CRANKSHAFT........................9-56
SPROCKET - REMOVAL, CRANKSHAFT.....9-55
STANDARD PROCEDURE - CLEANING.....9-31
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK........................9-47
STANDARD PROCEDURE - INSPECTION....9-32
STANDARD PROCEDURE, CAMSHAFT
END-PLAY...........................9-23
STANDARD PROCEDURE, COOLING
SYSTEM - REVERSE FLUSHING..........7-12
STANDARD PROCEDURE, CRANKSHAFT
END PLAY ...........................9-33
STANDARD PROCEDURE, CYLINDER
BORE HONING........................9-31
STANDARD PROCEDURE, DRAINING
COOLING SYSTEM....................7-11
STANDARD PROCEDURE, ENGINE CORE
AND OIL GALLERY PLUGS...............9-9
STANDARD PROCEDURE, ENGINE
GASKET SURFACE PREPARATION.........9-11
STANDARD PROCEDURE, ENGINE OIL
AND FILTER CHANGE..................9-47
STANDARD PROCEDURE, FLUSHING
COOLERS AND TUBES.................7-30
STANDARD PROCEDURE, FORM-IN-
PLACE GASKETS AND SEALERS..........9-10
STANDARD PROCEDURE, HYDROSTATIC
LOCKED ENGINE.......................9-9
STANDARD PROCEDURE, LAMP BAR
AIMING............................8L-65
STANDARD PROCEDURE, MAIN BEARING
- FITTING
............................9-35
STANDARD PROCEDURE, MEASURING
BEARING CLEARANCE USING
PLASTIGAGE
.........................9-11
STANDARD PROCEDURE, PISTON TO
CYLINDER BORE FITTING
...............9-30
STANDARD PROCEDURE, REFILLING
COOLING SYSTEM
....................7-11
STANDARD PROCEDURE, REPAIR OF
DAMAGED OR WORN THREADS
...........9-9
6 INDEXKJ
Description Group-Page Description Group-Page Description Group-Page

STOP LAMP BULB - INSTALLATION,
CENTER HIGH MOUNTED..............8L-19
STOP LAMP BULB - REMOVAL, CENTER
HIGH MOUNTED.....................8L-18
STOP LAMP UNIT - INSTALLATION,
CENTER HIGH MOUNTED..............8L-19
STOP LAMP UNIT - REMOVAL, CENTER
HIGH MOUNTED.....................8L-19
STRUCTURAL COLLAR - INSTALLATION....9-44
STRUCTURAL COLLAR - REMOVAL.......9-44
SURFACE PREPARATION - STANDARD
PROCEDURE, ENGINE GASKET...........9-11
SUSPENSION ARM BUSHING -
INSTALLATION, LOWER.................2-8
SUSPENSION ARM BUSHING -
INSTALLATION, UPPER..................2-8
SUSPENSION ARM BUSHING -
REMOVAL, LOWER.....................2-7
SUSPENSION ARM BUSHING -
REMOVAL, UPPER......................2-7
SUSPENSION, SPECIAL TOOLS - FRONT....2-1
SUSPENSION, SPECIAL TOOLS - REAR.....2-6
SWITCH - DESCRIPTION, BACKUP LAMP . . 8L-15
SWITCH - DESCRIPTION, BRAKE LAMP . . . 8L-16
SWITCH - DESCRIPTION, HAZARD.......8L-28
SWITCH - DESCRIPTION, HEADLAMP
LEVELING..........................8L-37
SWITCH - DESCRIPTION, LAMP BAR.....8L-67
SWITCH - DESCRIPTION, MULTI-
FUNCTION..........................8L-46
SWITCH - DIAGNOSIS AND TESTING,
BACKUP LAMP......................8L-15
SWITCH - DIAGNOSIS AND TESTING,
BRAKE LAMP.......................8L-17
SWITCH - DIAGNOSIS AND TESTING,
HEADLAMP LEVELING.................8L-37
SWITCH - DIAGNOSIS AND TESTING,
MULTI-FUNCTION....................8L-50
SWITCH - INSTALLATION, BRAKE LAMP . . 8L-18
SWITCH - INSTALLATION, HAZARD......8L-30
SWITCH - INSTALLATION, HEADLAMP
LEVELING..........................8L-38
SWITCH - INSTALLATION, LAMP BAR....8L-67
SWITCH - INSTALLATION, MULTI-
FUNCTION..........................8L-53
SWITCH - OPERATION, BACKUP LAMP . . . 8L-15
SWITCH - OPERATION, BRAKE LAMP.....8L-16
SWITCH - OPERATION, HAZARD.........8L-29
SWITCH - OPERATION, HEADLAMP
LEVELING..........................8L-37
SWITCH - OPERATION, MULTI-FUNCTION . 8L-48
SWITCH - REMOVAL, BRAKE LAMP......8L-17
SWITCH - REMOVAL, HAZARD..........8L-29
SWITCH - REMOVAL, HEADLAMP
LEVELING..........................8L-38
SWITCH - REMOVAL, LAMP BAR........8L-67
SWITCH - REMOVAL, MULTI-FUNCTION . . . 8L-53
SYSTEM - DESCRIPTION, EXHAUST.......11-1
SYSTEM - DIAGNOSIS AND TESTING,
EXHAUST............................11-2
SYSTEM - OPERATION, COOLING..........7-2
SYSTEM - REVERSE FLUSHING -
STANDARD PROCEDURE, COOLING.......7-12
SYSTEM - STANDARD PROCEDURE,
DRAINING COOLING...................7-11
SYSTEM - STANDARD PROCEDURE,
REFILLING COOLING...................7-11
SYSTEM 2.4L ENGINE - DESCRIPTION,
COOLING.............................7-1
SYSTEM DIAGNOSIS CHART -
DIAGNOSIS AND TESTING, COOLING.......7-5
SYSTEM LEAKS - DIAGNOSIS AND
TESTING, COOLING.....................7-2
TEMPERATURE SENSOR - DESCRIPTION,
ENGINE COOLANT.....................7-21
TEMPERATURE SENSOR -
INSTALLATION, ENGINE COOLANT........7-22
TEMPERATURE SENSOR - OPERATION,
ENGINE COOLANT.....................7-21
TEMPERATURE SENSOR - REMOVAL,
ENGINE COOLANT.....................7-21TENSIONER & PULLEY - INSTALLATION,
TIMING BELT.........................9-59
TENSIONER & PULLEY - REMOVAL,
TIMING BELT.........................9-59
TEST - DIAGNOSIS AND TESTING,
CYLINDER COMBUSTION PRESSURE
LEAKAGE.............................9-3
TEST - DIAGNOSIS AND TESTING,
CYLINDER COMPRESSION PRESSURE......9-3
TESTING, BACKUP LAMP SWITCH -
DIAGNOSIS.........................8L-15
TESTING, BRAKE LAMP SWITCH -
DIAGNOSIS.........................8L-17
TESTING, COOLING SYSTEM DIAGNOSIS
CHART - DIAGNOSIS....................7-5
TESTING, COOLING SYSTEM LEAKS -
DIAGNOSIS...........................7-2
TESTING, CYLINDER COMBUSTION
PRESSURE LEAKAGE TEST -
DIAGNOSIS...........................9-3
TESTING, CYLINDER COMPRESSION
PRESSURE TEST - DIAGNOSIS............9-3
TESTING, CYLINDER HEAD GASKET -
DIAGNOSIS..........................9-19
TESTING, ENGINE - DIAGNOSIS...........9-5
TESTING, ENGINE DIAGNOSIS -
PERFORMANCE - DIAGNOSIS.............9-5
TESTING, ENGINE MECHANICAL -
DIAGNOSIS...........................9-7
TESTING, ENGINE OIL LEAK
INSPECTION - DIAGNOSIS...............9-4
TESTING, ENGINE OIL PRESSURE
CHECKING - DIAGNOSIS................9-46
TESTING, EXHAUST SYSTEM -
DIAGNOSIS..........................11-2
TESTING, FRONT FOG LAMP RELAY -
DIAGNOSIS.........................8L-23
TESTING, HEADLAMP HIGH BEAM
RELAY - DIAGNOSIS
..................8L-34
TESTING, HEADLAMP LEVELING SWITCH
- DIAGNOSIS
........................8L-37
TESTING, HEADLAMP LOW BEAM RELAY
- DIAGNOSIS
........................8L-40
TESTING, INTAKE MANIFOLD LEAKS -
DIAGNOSIS
..........................9-51
TESTING, LAMP BAR - DIAGNOSIS
......8L-65
TESTING, LAMPS/LIGHTING - EXTERIOR
- DIAGNOSIS
.........................8L-7
TESTING, LASH ADJUSTER (TAPPET)
NOISE DIAGNOSIS - DIAGNOSIS
.........9-28
TESTING, MULTI-FUNCTION SWITCH -
DIAGNOSIS
.........................8L-50
TESTING, ON-BOARD DIAGNOSTICS
(OBD) - DIAGNOSIS
....................7-2
TESTING, PARK LAMP RELAY -
DIAGNOSIS
.........................8L-55
TESTING, PRELIMINARY CHECKS -
DIAGNOSIS
...........................7-2
TESTING, RADIATOR PRESSURE CAP -
DIAGNOSIS
..........................7-25
TESTING, REAR FOG LAMP RELAY -
DIAGNOSIS
.........................8L-57
TESTING, SERPENTINE DRIVE BELT
DIAGNOSIS - DIAGNOSIS
...............7-15
TESTING, TRAILER TOW RELAY -
DIAGNOSIS
.........................8L-62
THREADS - STANDARD PROCEDURE,
REPAIR OF DAMAGED OR WORN
..........9-9
TIMING BELT - INSTALLATION
...........9-56
TIMING BELT - REMOVAL
...............9-55
TIMING BELT COVER(S) - INSTALLATION
. . . 9-53
TIMING BELT COVER(S) - REMOVAL
......9-53
TIMING BELT TENSIONER & PULLEY -
INSTALLATION
........................9-59
TIMING BELT TENSIONER & PULLEY -
REMOVAL
...........................9-59
TIMING, INSTALLATION - BALANCE
SHAFT
..............................9-61TO CYLINDER BORE FITTING -
STANDARD PROCEDURE, PISTON........9-30
TOOLS - 2.4L ENGINE, SPECIAL..........9-17
TOOLS - COOLING, SPECIAL.............7-13
TOOLS - FRONT SUSPENSION, SPECIAL....2-1
TOOLS - REAR SUSPENSION, SPECIAL.....2-6
TORQUE - SPECIFICATIONS.............9-16
TORQUE, SPECIFICATIONS..............7-13
TOW CONNECTOR - INSTALLATION,
TRAILER...........................8L-61
TOW CONNECTOR - REMOVAL, TRAILER . . 8L-61
TOW RELAY - DESCRIPTION, TRAILER....8L-62
TOW RELAY - DIAGNOSIS AND TESTING,
TRAILER...........................8L-62
TOW RELAY - INSTALLATION, TRAILER . . . 8L-63
TOW RELAY - OPERATION, TRAILER.....8L-62
TOW RELAY - REMOVAL, TRAILER.......8L-63
TOW WIRING - DESCRIPTION, TRAILER . . 8L-64
TRAILER TOW CONNECTOR -
INSTALLATION.......................8L-61
TRAILER TOW CONNECTOR - REMOVAL . . 8L-61
TRAILER TOW RELAY - DESCRIPTION....8L-62
TRAILER TOW RELAY - DIAGNOSIS AND
TESTING...........................8L-62
TRAILER TOW RELAY - INSTALLATION . . . 8L-63
TRAILER TOW RELAY - OPERATION......8L-62
TRAILER TOW RELAY - REMOVAL.......8L-63
TRAILER TOW WIRING - DESCRIPTION . . . 8L-64
TRANS COOLER - DESCRIPTION.........7-30
TUBES - STANDARD PROCEDURE,
FLUSHING COOLERS...................7-30
UNIT - ADJUSTMENT, FRONT FOG LAMP . . 8L-25
UNIT - ADJUSTMENT, HEADLAMP.......8L-42
UNIT - INSTALLATION, CENTER HIGH
MOUNTED STOP LAMP................8L-19
UNIT - INSTALLATION, FRONT FOG
LAMP..............................8L-25
UNIT - INSTALLATION, FRONT LAMP.....8L-28
UNIT - INSTALLATION, HEADLAMP.......8L-42
UNIT - INSTALLATION, LICENSE PLATE
LAMP..............................8L-46
UNIT - INSTALLATION, REAR LAMP......8L-60
UNIT - INSTALLATION, REPEATER LAMP . . 8L-61
UNIT - REMOVAL, CENTER HIGH
MOUNTED STOP LAMP
................8L-19
UNIT - REMOVAL, FRONT FOG LAMP
.....8L-24
UNIT - REMOVAL, FRONT LAMP
.........8L-27
UNIT - REMOVAL, HEADLAMP
..........8L-41
UNIT - REMOVAL, LICENSE PLATE LAMP
. . 8L-45
UNIT - REMOVAL, REAR LAMP
..........8L-59
UNIT - REMOVAL, REPEATER LAMP
......8L-61
UPPER BALL JOINT - INSTALLATION
.......2-6
UPPER BALL JOINT - REMOVAL
...........2-6
UPPER CONTROL ARM BUSHINGS -
INSTALLATION
.........................2-4
UPPER CONTROL ARM BUSHINGS -
REMOVAL
............................2-3
UPPER SUSPENSION ARM BUSHING -
INSTALLATION
.........................2-8
UPPER SUSPENSION ARM BUSHING -
REMOVAL
............................2-7
USING PLASTIGAGE - STANDARD
PROCEDURE, MEASURING BEARING
CLEARANCE
..........................9-11
VALVES & SEATS - CLEANING,
INTAKE/EXHAUST
.....................9-27
VALVES & SEATS - DESCRIPTION,
INTAKE/EXHAUST
.....................9-27
VIBRATION DAMPER - INSTALLATION
.....9-43
VIBRATION DAMPER - REMOVAL
.........9-43
WATER PUMP - 2.4L - DESCRIPTION
......7-27
WATER PUMP - 2.4L - INSPECTION
.......7-28
WATER PUMP - 2.4L - OPERATION
.......7-27
WIRING - DESCRIPTION, TRAILER TOW
. . 8L-64
WORN THREADS - STANDARD
PROCEDURE, REPAIR OF DAMAGED
OR
..................................9-9
KJINDEX 7
Description Group-Page Description Group-Page Description Group-Page

JEEP LIBERTY 2002
SPARE WHEEL & HARDWARE19-020-<8)
21-522~
23 .lLI
11
b
RACK & PINION10
~66~ -
24I14~
~2~
!
31~J~L2S--£3J
!;:;q)17
118-#~ I~
12~
/~004-09516 ~~'"
5~132616A-15~~
1 Wheel, Spare 14Steel 5GL65S4AAA 160.00 16 004 09907Alloy --
16x7Code WLD 10 Arm, Upper Control AiL 52088632AA m #2.0 128.00To 10-1-01 5GL67PAKAA 249.00 #W/Steering Knuckle Assy Removed Deduct 1.2 004 09522 c~From 10-1-01 5GL67PAKAB 24900 11 Bum~r, Control Arm AiL 52088684AB m 25.75 -
Code WND 5GL66PAKAB 260'00 12 Knuckle Assy, Steering R 52088652AA m #1.7 127.0017x7.5 .L 52088653AA m #1.7 127.00 1 Gear Assy, SteeringCode WGO 5HW90ZDRM 249.00 #/ncludes R&R Brake Rotor and Hub & Bearing Assy, 2.4L Eng 52128588M m #1.9 484.00Code WGR 5HW90AFMAA 24900 R&R Both Sides 3.2 37L Eng 52128518M m #1.9 459.002 Jack 52059104 83:35 13 Joint, Lower Balll] AiL 5069161AB m 2.0 27.50 #W/4WD Add 3.63 Wrench, Lug 52059478AA 12.85" l]/nc/uded w/Steering Knuckle Assy 2 Boot, Steering Gear1J AiL 5O72446M m 57.104 Bracket, Jack 52059369M 16.35!114Arm,LowerControl R 52088636AD m#2.2 117.00 3Bolt,Mountingl] AiL 6506517M 7.505 Label, Jack Instructions-See InforrnatJon Labels SectJon L 52088637AD m #2.2 117.00 4 Nut, MountJng:~ AiL 6504707 2.456 Bracke~ Spare. Wheel 55155933AB 59.10 #Includes R&R Bushings, w/Steering Knuckle 5 Bushing, Steering Gear1J AiL 52038783AB 15.20Cover, :opare Tire 5JG141X7M Removed Deduct.9 l1/nc/uded w/Steering Gear AssyAiL 52088746M m 12.25 6 Rod, Outer Tie R 5O72444M 46.70AiL 52088649AC m L 5072445M 46.70
AIL 6507080AA18 Bolt, Lower Carn (2/Side) AiL 6507321M19 Nut, Absorber AiL 6506443M 1.5020 Retainer, Absorber AiL 52089069M 2.25 2.4L ENG21 Mount, Absorber R 52128532AA m #1.8 91.70L 52128533AA m #1.8 91.7022 Isolator, Upper Spring AiL 52088686M m #1.8 16.25 423 Springl] AiL 52088625M m #1.8 35.75~.tr24 Absorber, Shock11 AiL 52088650AB m #1.8 36.95 111Additional Parts &lor Dealer Contact Required 0 3125 Isolator, Lower Spring AiL 52088686M m #1.8 16.25 -
I #R&R One Side Complete, Includes R&R ClevisAbsorber, w/Steering Knuckle Assy Removed Deducr ~.7, R&R Both Sides 3.426 Clevis, Absorber AiL 52088748AC m #.6 49.75#W/Steering Knuckle Assy Removed Deduct.4
29\",~~-l 004-09908
27 Retainer, Stab Bar AiL 52088631M m #.3 9.70 I128 Bushing, Slab Bar AiL 52088778M m #.3 4.60 c 004 09909#R&R One Side Complete, Not Included in O/H! -
29 Link, Stab Bar Ail 52088662AB m #.3 43.75PS.#Not Included in O/H 1 ump, teerlng30 Bar, Stabilizer 52088660M m #.8 98.25 2 Pulley, ~ump#Includes R&R Stab Bar Links, Bushings & Retainers 3 Reservoir, Pu~pNot Included in O/H 4 Cap, Reservoir.Bracket, Reservoir
6
~",,3
2
m .3m .3
52
Use Procedure Explanation 11 with the following text.
R&I Suspension/Sub.Frame Assy2WD m#2.74 WD m #3.6#Not Included in O/H SuspensionO/H SuspensionOne Side , R/Lm 4.7Both Sides. m 8.4Bleed Brake Systemw/ABS m .6w/oABS m .3AdjustFrontAlignment m 1.5NOTE 1: R&UR&R or O/H Does Not include alignment or bleedbrake system.
NOTE 2: All Parts in this section are included in overhaulunless noted otherwise.
/1
I'~~II::It
52088711AA m 1.7 130.0053031722AA m 21.6052088713AA m .5 40.2552128513AA 10.4552088874AD 43.4552088722AC m .8 163.0052088718AC m 23.4552128561AA m .9 174.00
5
~L-7 Cooler, SteeringR&I Axle Housing Assy m 3.0R&I Outer Axle Shaft Assy R/Lm #1.5#WlSteering Knuckle Assy Removed Deduct .93.7L ENG
4004-09906
004-09520
1 Nut, Axle AiL 6506454AA m 8.502 Rotor, Brake AiL 52128247AA m #.9 104.00#R&R Both Sides 1.63 Caliper, Brake R 5066422AA m #.5 182.00 IL 5066423AA m #.5 182.00 I4 Bracket, Caliper Mounting AIL 5019986AA m #.5 42.50#R&R One Side Complete, w/Brake Rotor RemovedDeduct .3, R&R Both Sides .85 Pad Set, Brake 5066427AA m #1.0 128.00#Deduct .5 for Each Brake Caliper Removed6 Hub & Bearingw/ABS R 52128692AA m #1.3 259.00L 52128693AA m #1.3 259.00w/o ABS AiL 52128352AB m #1.3 259.00I#Includes R&R Brake Rotor, R&R Both Sides 2.47 Stud, Wheel AiL 6O36388AA m 2.958 Sensor, Front ABS-See ABSIBrakes Section9 Hose, Front Brake R 52128312AA m #.3 18.35L 52128311AA m #.3 18.35#W/Caliper Removed Deduct .2
567Procedure Explanation Pages Must Be Used with the Above Text for an Accura'~ Damage Report.Comments or suggestions? Need assistance? Call 1-800-854-7030 or 858/578-6550, Ext 8220. Fax 1-888-256-7969 or 858/549-0629.CH
R&I Steering Gear Assy m #1.7#W/4WD Add 3.6
NOTE: R&R Does Not include adjust wheel alignment.~
6~9 2
67rl1
~'~
3 2,
51 Shaft Assy, Outer Axle f IA
~,::;~~~~2.4LEng R 5066022AA m#1.5 994.00cJ1y L 5066023AA m #1.5 1155.00'
3.7L Eng R 5066020AA m #1.5 1020.00L 5066021AA m #1.5 1155.00#WlSteering Knuckle Assy Removed Deduct .92 Boot Kit, Inner1j AiL 5066024AA m 26 203 Boot Kit, Outer1j AiL 5066025AA m 25:50~/ncluded w/Outer Axle Shaft Assy 004-09524
Bracket, Mountin~2.4L Eng R 52059472AB m 81.85 1 PumplReservoir. Assy, Steering 52088710AA m 2.4 130.00L 52059473AB m 54.50 2 Cap, Reservolr1j 52088956AA 27.453.7L Eng R 52059464AB m 81.85 ~/ncluded w/Steering Pumf)/ReseIVo;r AssyL 52059465AB m 30.85 I 3 Pulley, Pump 5:3010258AC m #.3 20.25

JEEP LIBERTY 2002
QUARTER GLASS Conf'd410
OjJ.::::::::~~~~::::::::::;;;')t';
0.000.000.000.00
,...,.,,-
Privacyw/Antenna A 55360056AB #1.5L 55235923AB #1.5w/o Antenna A 55235922AB #1.5L 55235923AB #1.5NAGSTintedw/Antenna A DQO9990GTN #1.5 0.00L DQO9989GTN #1.5 302.751w/o Antenna AIL DO09988-9GTN #1.5 302.75Privacyw/Antenna A DO10069YPN #1.5 270.85L DQ10068YPN #1.5 297.95w/o Antenna AIL DO10067-8YPN #1.5 297.95#Includes Clean Up Old Adhesive as Necessary2 Spacer, Glass (4) 55360509M .35
32~
3~4~004-09943
55156554M55156275AB55156405M55156277M
Decal, Aear Gate1 "Jeep""3.7L""CAD"4 "Up Country"Use Procedure Explanations 25 and 28 with the fol/owing text.
R&IGlassAssy 3~
R&I Trim Panel ~~~~
~ '
.2~2 3
1\11 ..1-1[1\1
4~ '--004-09573-J2~
j~
.2 22.85 2 004-09575.2 13.101.2 25.45 1 Drum, Brake Ail 52128270AA m '.3 85.00.2 11.00 #R&R Both Sides.52 Shoe Set, Brake 5O66147AA m 11.4 108.00#Includes R&R Brake Drums3 Plate, Backing R 5066150AA m #.3 30.45l 506615tAA m #.3 30.45#W/Axle Shaft Assy Removed4 Shaft Assy, Axle R 5066484AA m.7 294.00l 5O66485AA m.7 295.005 Studl Wheell1 (5/Side) Ail 5016496AA m 1.2516 Retainer, Axle~ Ail 5O66486AA m'1.1 9.007 Seal, Axle~ Ail 5O12824AA m'1.1 3.458 Bearing, Axle1[ Ail 5012825AA m #1.1 56.509 Retainer, Beann9~ Ail 5O72894AA m #1.1 12.25~Included w/Axle Shaft Assy#R&R One Side Com~lefeSensor, Rear ABS-See ABS7Brakes Section10 Housing Assy, AxIe1] 5O66495AB m #5,0 1485.00~Additional Parts &/or Dealer Contact RequiredHousing, Axle (a) 5O66477AA m 17.7 817.00(a) Included w/Axle Housing Assy#Includes R&R Axle Shafts Assemblies
1 GlassChrYslerTinted 55360340AB.6 458.00Pnvacy 55360342AB650000NAGS ..
Tinted DBO9991GTY.6 1042.75 004-09572Pnvacy DBO9991YPY.6 1177301.Solar DB10070YPY.6 1177:30 1 Panel,RearGaIeTrlm~2 Hinge, Glass R 55360216AB #.4 23.95 wlStorage NetL 55360217AB #.4 23.95 Slate Gray#R&R Both Sides .5, Included in R&R Glass Taupe3 Stay, Glass AiL 55360171AA 2 3135 wlo Storage Net4 Striker, Glass 55360220AA #:2 21:50 Slate Gray#Included in R&R Glass Taupe
SHE6S)(DVACSHE6S\'lL5AC
SGE69;(DVACSGE69"lL5AC
.2 220.00.2 220.00
.2 125.00.2 125.00
#.1 20.4555360309M#WlTrim Panel Removed17111
WIPER SYSTI:MUse Procedure Explanations 25 and 28 with the fol/owing text.
SHEET METAUHARDWAREr10
1--17.l1
19-f1 ~21
~ E:-22 24
23~ ~~~
~~:==~~Y~::C:;==::~~O9576
11 Arm Assy, Upper Control 52088901AB m .8 212.0012 Joint, Ball~ 52088647M m #.3 50.0013 Bushing, Control Arm~ AiL 52086425 m #.2 11.95#W/Upper Control Arm Assy Removed.1 16.60 14 Bracket, Ball Join~ 52088894M m 56.25#.2 20.45 15 Bolt, Bracke~ 6503610 2.2016 Nu1, Bo~ 6503711 1'.451.60 ~/ncluded wlUpper Control Ann Assy4.95 17 Bolt, No.1 Mounting AiL 6504748 3.851.60 18 Bolt, No.2 Mounting (3) 6505445M 2.455.50 19 Absorber, Shock AiL 52088673AB m #.4 0.005.60 #R&R Both Sides .6, wlCoil Spring Removed Deduct .37.75 20 Isolator, Upper Spring AiL 52088707AA m 7.85#.3 125.00 1 Bumper, Ul?per AiL 52088705AB m 16.602 Spring, ColI'l AiL 52088695AB m #.6 54.95#.2 7.95 1jAdditlonal Palts &/or Dealer Contact Required#R&R Both Sides 1.0AiL 52128524M m 17.95AiL 52088682AB m #.6 102.00#WIAxle Housing Removed Deduct .325 Bar, Stabilizer 52088677AB m .5 127.00
~~~ "I fJ-s
9
~
Refinish Rear Gate Panel Outside 2.0Add for Jambs & Interior 1.0RefinishUpperGateHinge .2Refinish Lower Gate Hinge .2R&I Rear Gale Assy #1.4#Includes R&VR&R Left Qualter Trim PanelR&I Outside Handle #.4#Includes R&I Trim PanelR&ISpareTireBracket .2
7 56 I 8
l.s~-10 m'-
I004-09574 ---
1 Blade, Wiper 5066964AA2 Arm, Wiper 5066965AA#Includes R&R Wiper Blade3 Cover, Wiper Arm 550766504 Nut, Wiper Arm 65001655 Cover, Motor 550766506 Nut, Motor 65022637 Bezel, Motor 55155B87AA8 Stop, Wiper 5515~~86AA9 Motor, Wiper 55155e:84AA#w!rrim Panel Removed10 Nozzle, Washer 55156158AA#Included in R&R Roof Panel
4WD
4
-~~_~~~7~"'- --~3~ 1 ~~ 004-09570
1 Panel, Rear Gate 55176934AC #4.0 375.00#Includes R&VR&R Left Qualter Trim Panel2 Hinge, GateUpper 52850558AA #.2Lower 52850559AA #.2#WlRear Gate Assy RemovedCheck, Gate 55360170AA #.2 38.8513 Latch, Glass 55360357 AA #.2 70.85 Use Procedure Explanation 23 with the following text.Latch, Gate 55360359AA #.2 55.754 Handle, Outside 55360331AC #.35 Weatherstrip, Upper Gate 55360065AA #.2 -14.10 I#Wnrim Panel Removed6 Sta.bilizer, Gate 55360324AC 6.20 l R&I Suspension/Axle Assy .m 3.07Stnker 55176954AA.2 12.60~ Check Rear Alignment .m .88 Spacer, Striker 5507548.3 1.50, Add to Adjustrront Alignment9Bracket,SpareWheel-SeeWheelSecllon 2WD m .710 Weatherstrip, Rear 55716958AA .2 0.00 4WD m 1.0Bleed Brake Systemwi ABS m .6w/oABS m .3
NOTE: R&I/R&R Does Not include illignment or bleed brakesystem
Illustration Located in Next Column
1 Drum, Brake AIL 52128270AA m #.3 85.00#R&R Both Sides .52 Shoe Set, Brake 5066147AA m #1.4 108.00#Includes R&R Brake Drums3 Plate, Backing R 5066150AA m #.3 30.45L 5066151AA m #.3 30.45#W/Axle Shaft Assy Removed
labor Times Shown are for Replacement with New OEM Undamaged Parts on New Undamaged Vehicles.Comments or suggestions? Need assistance? Call1-80D-854-7030 or 8!i8/578-6550, Ex1 8220. Fax 1-888-256-7969 or 858/549-0629.576CH

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
2SSuspension
3Differential & Driveline
5Brakes
5SBrakes
6Clutch
7Cooling
7SCooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8LSLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
9SEngine
11Exhaust System
11SExhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
2.4L Gas Component and System Index
Service Manual Comment Forms
NOTE: For New Vehicle Preparation information, see the separate
publication, 81-170-00003.
NOTE: Group names with the suffix(S(indicate groups pertaining to the
the 2.4L Gas Supplement

FASTENER USAGE
DESCRIPTION
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 3) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 3 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
4 INTRODUCTIONKJ