engine block JEEP LIBERTY 2002 KJ / 1.G Repair Manual

8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
A/C Compressor Clutch Relay.......... 8Wa-31-3
Auto Shut Down Relay............... 8Wa-31-3
Back-Up Lamp Switch............... 8Wa-31-4
Brake Lamp Switch................. 8Wa-31-5
Crankshaft Position Sensor............ 8Wa-31-6
Data Link Connector................. 8Wa-31-6
Diagnostic Junction Port.............. 8Wa-31-3
Engine Control Module............... 8Wa-31-6
Fuel Pump Relay................... 8Wa-31-3
Fuse 5............................ 8Wa-31-2
Fuse 15........................... 8Wa-31-3
Fuse 28........................... 8Wa-31-3
Fuse 38........................... 8Wa-31-5
Fuse 39........................... 8Wa-31-4
G102........................... 8Wa-31-7, 9
G111 ............................. 8Wa-31-2
G301............................. 8Wa-31-5
Input Speed Sensor.................. 8Wa-31-9Component Page
Instrument Cluster.................. 8Wa-31-5
Junction Block.................. 8Wa-31-3, 4, 5
Left Tail/Stop Lamp................. 8Wa-31-4
Line Pressure Sensor................ 8Wa-31-9
Output Speed Sensor................ 8Wa-31-9
Power Distribution Center.......... 8Wa-31-2, 3
Powertrain Control Module........ 8Wa-31-3, 5, 6
Right Tail/Stop Lamp................ 8Wa-31-4
Shifter Assembly.................... 8Wa-31-5
Starter Motor Relay................. 8Wa-31-8
Throttle Position Sensor.............. 8Wa-31-5
Trailer Tow Connector................ 8Wa-31-4
Transfer Case Position Sensor.......... 8Wa-31-5
Transmission Control Module . . 8Wa-31-2, 3, 5, 6, 7,
8, 9
Transmission Control Relay....... 8Wa-31-2, 7, 8
Transmission Solenoid/Trs Assembly . . 8Wa-31-2, 4,
7, 8, 9
KJ8W-31 TRANSMISSION CONTROL SYSTEM8Wa-31-1

8W-33 VEHICLE SPEED CONTROL
Component Page
Body Control Module................ 8Wa-33-5
Brake Lamp Switch................. 8Wa-33-2
Clockspring.................... 8Wa-33-3, 4, 5
Controller Antilock Brake............. 8Wa-33-2
Engine Control Module............... 8Wa-33-5
Fuse 12........................... 8Wa-33-2
G112 ............................. 8Wa-33-2Component Page
G202............................. 8Wa-33-2
Junction Block..................... 8Wa-33-2
Left Speed Control Switch............. 8Wa-33-4
Powertrain Control Module.......... 8Wa-33-2, 3
Right Speed Control Switch........... 8Wa-33-4
Shifter Assembly.................... 8Wa-33-2
Speed Control Servo................. 8Wa-33-2
KJ8W-33 VEHICLE SPEED CONTROL8Wa-33-1

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module............. 8Wa-40-4, 8
Body Control Module........... 8Wa-40-3, 4, 5, 8
Controller Antilock Brake............. 8Wa-40-6
Data Link Connector................. 8Wa-40-4
Diagnostic Junction Port...... 8Wa-40-4, 5, 6, 7, 8
Driver Seat Belt Switch.............. 8Wa-40-8
Engine Control Module............... 8Wa-40-6
Engine Coolant Level Sensor.......... 8Wa-40-3
Fuse 9............................ 8Wa-40-3
Fuse 13........................... 8Wa-40-2
Fuse 34........................... 8Wa-40-2
G103............................. 8Wa-40-3Component Page
G111 ............................. 8Wa-40-3
G202........................... 8Wa-40-2, 3
Hazard Switch/Combination Flasher..... 8Wa-40-3
Instrument Cluster........ 8Wa-40-2, 3, 4, 5, 7, 8
Junction Block.................... 8Wa-40-2, 3
Park Brake Switch.................. 8Wa-40-5
Park Lamp Relay................... 8Wa-40-3
Passenger Seat Belt Switch............ 8Wa-40-8
Powertrain Control Module............ 8Wa-40-6
Red Brake Warning Indicator Switch.... 8Wa-40-3
Transmission Control Module.......... 8Wa-40-6
Washer Fluid Level Switch............ 8Wa-40-2
KJ8W-40 INSTRUMENT CLUSTER8Wa-40-1

8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Clutch............. 8Wa-42-5, 7
A/C Compressor Clutch Relay........ 8Wa-42-5, 7
A/C High Pressure Switch............. 8Wa-42-6
A/C Low Pressure Switch........... 8Wa-42-3, 6
A/C Pressure Transducer............. 8Wa-42-5
A/C- Heater Control............... 8Wa-42-2, 4
Auto Shut Down Relay............... 8Wa-42-5
Blend Door Actuator................. 8Wa-42-2
Blower Motor................... 8Wa-42-3, 4, 6
Blower Motor Relay.............. 8Wa-42-3, 4, 6
Blower Motor Resistor Block....... 8Wa-42-3, 4, 6
Body Control Module................ 8Wa-42-4
Cabin Heater....................... 8Wa-42-7
Cabin Heater Relay.................. 8Wa-42-7
Defogger Relay..................... 8Wa-42-2
Engine Control Module............. 8Wa-42-6, 7
Fuel Heater Relay................. 8Wa-42-3, 6
Fuel Pump Relay................... 8Wa-42-5Component Page
Fuse 1.......................... 8Wa-42-3, 6
Fuse 15........................... 8Wa-42-5
Fuse 16........................... 8Wa-42-7
Fuse 19........................... 8Wa-42-6
Fuse 21......................... 8Wa-42-5, 7
Fuse 24........................... 8Wa-42-3
Fuse 25........................... 8Wa-42-2
Fuse 30........................... 8Wa-42-2
G101............................. 8Wa-42-5
G103........................... 8Wa-42-5, 7
G111 ........................... 8Wa-42-3, 6
G112 ........................... 8Wa-42-3, 6
G200............................. 8Wa-42-4
G202............................. 8Wa-42-2
Instrument Cluster.................. 8Wa-42-4
Junction Block.............. 8Wa-42-2, 3, 4, 5, 6
Power Distribution Center....... 8Wa-42-3, 5, 6, 7
Powertrain Control Module.......... 8Wa-42-3, 5
KJ8W-42 AIR CONDITIONING-HEATER8Wa-42-1

8W-45 BODY CONTROL MODULE
Component Page
A/C- Heater Control................. 8Wa-45-5
Ambient Temperature Sensor.......... 8Wa-45-7
Body Control Module . 8Wa-45-10, 11, 2, 3, 4, 5, 6, 7,
8, 9
Brake Lamp Switch................. 8Wa-45-2
Cargo Lamp..................... 8Wa-45-4, 8
Clockspring........................ 8Wa-45-5
Controller Antilock Brake............. 8Wa-45-5
Data Link Connector............. 8Wa-45-10, 11
Defogger Relay..................... 8Wa-45-3
Diagnostic Junction Port.............. 8Wa-45-6
Door Lock Relay.................... 8Wa-45-4
Driver Door Unlock Relay............. 8Wa-45-3
Engine Control Module............... 8Wa-45-5
Flip-Up Glass Release Motor........... 8Wa-45-8
Flip-Up Glass Release Switch.......... 8Wa-45-8
Front Fog Lamp Relay............... 8Wa-45-4
Fuse 3............................ 8Wa-45-7
Fuse 6............................ 8Wa-45-3
Fuse 13........................... 8Wa-45-2
Fuse 32........................... 8Wa-45-2
Fuse 34........................... 8Wa-45-2
G111 ............................. 8Wa-45-7
G202........................... 8Wa-45-2, 6
G300............................. 8Wa-45-9
G302............................. 8Wa-45-9
Hazard Switch/Combination Flasher..... 8Wa-45-5
High Beam Relay................... 8Wa-45-3
Hood Ajar Switch................... 8Wa-45-7
Horn Relay........................ 8Wa-45-7
Ignition Switch..................... 8Wa-45-6
Instrument Cluster.................. 8Wa-45-6Component Page
Junction Block.............. 8Wa-45-2, 3, 4, 7, 8
Left Courtesy Lamp................. 8Wa-45-4
Left Cylinder Lock Switch....... 8Wa-45-10, 11, 4
Left Door Lock Switch.............. 8Wa-45-4, 7
Left Front Door Ajar Switch........... 8Wa-45-9
Left Front Door Lock Motor/Ajar
Switch...................... 8Wa-45-10, 11
Left Rear Door Ajar Switch............ 8Wa-45-9
Left Visor/Vanity Lamp............... 8Wa-45-3
Low Beam Relay.................... 8Wa-45-3
Multi- Function Switch........... 8Wa-45-3, 5, 6
Overhead Map/Reading Lamp........ 8Wa-45-3, 4
Park Lamp Relay................... 8Wa-45-3
Passenger Door Unlock Relay.......... 8Wa-45-3
Powertrain Control Module............ 8Wa-45-5
Rear Fog Lamp Relay................ 8Wa-45-2
Rear Wiper Motor................. 8Wa-45-6, 8
Remote Keyless Entry Module......... 8Wa-45-8
Right Courtesy Lamp................ 8Wa-45-4
Right Cylinder Lock Switch...... 8Wa-45-10, 11, 4
Right Door Lock Switch............ 8Wa-45-4, 7
Right Front Door Ajar Switch.......... 8Wa-45-9
Right Front Door Lock Motor/Ajar
Switch...................... 8Wa-45-10, 11
Right Rear Door Ajar Switch........... 8Wa-45-9
Right Remote Radio Switch............ 8Wa-45-5
Right Visor/Vanity Lamp.............. 8Wa-45-3
Tailgate Cylinder Lock Switch.... 8Wa-45-10, 11, 8
Tailgate Lock Motor/Ajar Switch...... 8Wa-45-7, 8
Washer Pump...................... 8Wa-45-6
Wiper High/Low Relay............... 8Wa-45-4
Wiper On/Off Relay.................. 8Wa-45-4
KJ8W-45 BODY CONTROL MODULE8Wa-45-1

Component Page
C316 (Built-Up-Export).............. 8Wa-80-46
C316 (Built-Up-Export).............. 8Wa-80-46
C317 (Except Built-Up-Export)........ 8Wa-80-47
C317 (Except Built-Up-Export)........ 8Wa-80-47
Cabin Heater (Diesel)............... 8Wa-80-47
Camshaft Position Sensor (2.4L)....... 8Wa-80-47
Camshaft Position Sensor (3.7L)....... 8Wa-80-47
Camshaft Position Sensor (Diesel)...... 8Wa-80-48
Capacitor......................... 8Wa-80-48
Cargo Lamp (Except Base)........... 8Wa-80-48
CD Changer...................... 8Wa-80-48
Center High Mounted Stop Lamp...... 8Wa-80-49
Cigar Lighter..................... 8Wa-80-49
Clockspring C1.................... 8Wa-80-49
Clockspring C2.................... 8Wa-80-49
Clockspring C3.................... 8Wa-80-49
Clutch Interlock Switch (M/T)......... 8Wa-80-50
Coil On Plug No. 1 (3.7L)............ 8Wa-80-50
Coil On Plug No. 2 (3.7L)............ 8Wa-80-50
Coil On Plug No. 3 (3.7L)............ 8Wa-80-50
Coil On Plug No. 4 (3.7L)............ 8Wa-80-50
Coil On Plug No. 5 (3.7L)............ 8Wa-80-51
Coil On Plug No. 6 (3.7L)............ 8Wa-80-51
Coil Rail (2.4L).................... 8Wa-80-51
Compass Mini-Trip Computer
(Premium)...................... 8Wa-80-51
Controller Antilock Brake............ 8Wa-80-52
Crankshaft Position Sensor (2.4L)...... 8Wa-80-52
Crankshaft Position Sensor (3.7L)...... 8Wa-80-52
Crankshaft Position Sensor (Diesel).... 8Wa-80-53
Data Link Connector................ 8Wa-80-53
Diagnostic Junction Port............. 8Wa-80-53
Dome Lamp (Base)................. 8Wa-80-54
Driver Airbag Squib 1............... 8Wa-80-54
Driver Airbag Squib 2............... 8Wa-80-54
Driver Seat Belt Switch............. 8Wa-80-54
Driver Seat Belt Tensioner........... 8Wa-80-54
EGR Solenoid (Diesel)............... 8Wa-80-55
Engine Control Module C1........... 8Wa-80-55
Engine Control Module C2........... 8Wa-80-56
Engine Coolant Level Sensor (Diesel) . . . 8Wa-80-57
Engine Coolant Temp Sensor (Diesel) . . . 8Wa-80-57
Engine Coolant Temperature
Sensor (Gas).................... 8Wa-80-58
Engine Oil Pressure Sensor........... 8Wa-80-58
Evap/Purge Solenoid................ 8Wa-80-58
Flip-Up Glass Release Motor.......... 8Wa-80-58
Flip-Up Glass Release Switch......... 8Wa-80-58
Front Wiper Motor................. 8Wa-80-59
Fuel Heater (Diesel)................ 8Wa-80-59
Fuel Injector No. 1 (Diesel)........... 8Wa-80-59
Fuel Injector No. 1 (Gas)............. 8Wa-80-59
Fuel Injector No. 2 (Diesel)........... 8Wa-80-59
Fuel Injector No. 2 (Gas)............. 8Wa-80-60Component Page
Fuel Injector No. 3 (Diesel)........... 8Wa-80-60
Fuel Injector No. 3 (Gas)............. 8Wa-80-60
Fuel Injector No. 4 (Diesel)........... 8Wa-80-60
Fuel Injector No. 4 (Gas)............. 8Wa-80-60
Fuel Injector No. 5 (3.7L)............ 8Wa-80-61
Fuel Injector No. 6 (3.7L)............ 8Wa-80-61
Fuel Pressure Sensor (Diesel)......... 8Wa-80-61
Fuel Pressure Solenoid (Diesel)........ 8Wa-80-61
Fuel Pump Module................. 8Wa-80-61
G202............................ 8Wa-80-61
Generator........................ 8Wa-80-62
Glow Plug Assembly (Diesel).......... 8Wa-80-62
Hazard Switch/Combination Flasher.... 8Wa-80-62
Headlamp Leveling Switch
(Built-Up-Export)................ 8Wa-80-63
Heated Seat Module (Highline)........ 8Wa-80-63
High Note Horn.................... 8Wa-80-63
Hood Ajar Switch (Except Base)....... 8Wa-80-63
Idle Air Control Motor............... 8Wa-80-64
Ignition Switch.................... 8Wa-80-64
Input Speed Sensor (3.7L)............ 8Wa-80-64
Instrument Cluster................. 8Wa-80-64
Intake Air Temperature Sensor (Gas) . . . 8Wa-80-65
Intrusion Sensor (Built-Up-Export)..... 8Wa-80-65
Junction Block Body Control Module-JB . 8Wa-80-65
Junction Block C1.................. 8Wa-80-66
Junction Block C2.................. 8Wa-80-67
Junction Block C3.................. 8Wa-80-68
Knock Sensor (3.7L)................ 8Wa-80-69
Leak Detection Pump............... 8Wa-80-69
Left Courtesy Lamp................ 8Wa-80-69
Left Curtain Airbag................. 8Wa-80-69
Left Cylinder Lock Switch (Except Base) . 8Wa-80-69
Left Door Lock Switch (Except Base) . . . 8Wa-80-70
Left Fog Lamp..................... 8Wa-80-70
Left Front Door Ajar Switch (Base)..... 8Wa-80-70
Left Front Door Lock Motor/Ajar Switch
(Except Base)................... 8Wa-80-70
Left Front Door Speaker (Base)........ 8Wa-80-70
Left Front Door Speaker (Premium).... 8Wa-80-71
Left Front Impact Sensor............ 8Wa-80-71
Left Front Park/Turn Signal Lamp..... 8Wa-80-71
Left Front Power Window Motor
(Midline/Highline)................ 8Wa-80-71
Left Front Wheel Speed Sensor (ABS) . . . 8Wa-80-72
Left Headlamp (Built-Up-Export)...... 8Wa-80-72
Left Headlamp (Except Built-Up-Export) . 8Wa-80-72
Left Heated Seat Assembly (Highline) . . . 8Wa-80-72
Left Heated Seat Switch (Highline)..... 8Wa-80-72
Left Instrument Panel Speaker........ 8Wa-80-73
Left Leveling Motor (Built-Up-Export) . . 8Wa-80-73
Left Position Lamp (Built-Up-Export) . . . 8Wa-80-73
Left Power Mirror (Except Base)....... 8Wa-80-73
8Wa - 80 - 2 8W-80 CONNECTOR PIN-OUTSKJ

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Blend Door Actuator BK Behind Right Side of
Instrument PanelN/S
Blower Motor BK Behind Right Side of
Instrument PanelN/S
Blower Motor Resistor Block BK Behind Right Side of
Instrument PanelN/S
Body Control Module C1 GY Under Left Side of
Instrument PanelN/S
Body Control Module C2 GY Under Left Side of
Instrument PanelN/S
Body Control Module C3 (Premium) Under Left Side of
Instrument PanelN/S
Boost Pressure Sensor (Diesel) Left Side of Engine 22
Brake Lamp Switch BK At Brake Pedal N/S
Brake Pressure Switch (ABS) BK On Master Cylinder N/S
C100 GY Left Kick Panel 32, 33, 37
C101 (2.4L) BK Left Side of Engine
Compartment11 , 1 2
C102 (RHD) Left Kick Panel 32
C103 (Gas) BK Right Rear Side of Engine
Compartment8, 9, 10, 13, 14, 16
C104 BK Right Rear Side of Engine
Compartment8, 9, 10, 13, 14, 16, 17,
18
C105 GY Right Rear Side of Engine
Compartment8, 9, 10, 13, 14, 16, 17,
18
C106 BK Left Front Side of Engine
Compartment29
C107 BK Left Front Side of Engine
CompartmentN/S
C108 (Gas) GY Left Front Side of Engine 30
C110 (2.4L) BK Left Side of Engine 11, 12
C111 (Diesel) LG Right Rear Side of Engine
Compartment17, 18
C112 (Gas) BK Right Side of Engine
Compartment8, 9, 10, 13, 14, 31
C113 (Diesel) LG Left Rear Side of Engine
CompartmentN/S
C114 (Diesel) LG Top of Engine N/S
C201 BK Behind Center of Instrument
PanelN/S
C202 YL Behind Center of Instrument
PanelN/S
C300 (LHD) OR Left A-Pillar 35, 41
C300 (RHD) OR Right A-Pillar 39, 41
C301 (LHD) OR Left A-Pillar 35, 41
C301 (RHD) OR Right A-Pillar 39, 41
8Wa - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONKJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Front Wiper Motor (RHD) BK Right Side of Cowl 24
Fuel Heater (Diesel) BK Left Rear Side of Engine
Compartment19
Fuel Injector No.1 (Diesel) BK At Fuel Injector 23
Fuel Injector No.1 (Gas) BK At Fuel Injector 1
Fuel Injector No.2 (Diesel) BK At Fuel Injector 23
Fuel Injector No.2 (Gas) BK At Fuel Injector 2
Fuel Injector No.3 (Diesel) BK At Fuel Injector 23
Fuel Injector No.3 (Gas) BK At Fuel Injector 1
Fuel Injector No.4 (Diesel) BK At Fuel Injector 22
Fuel Injector No.4 (Gas) BK At Fuel Injector 2
Fuel Injector No.5 (3.7L) BK At Fuel Injector 1
Fuel Injector No.6 (3.7L) BK At Fuel Injector 2
Fuel Pressure Sensor (Diesel) Left Side of Engine 22
Fuel Pressure Solenoid (Diesel) BK Left Side of Engine 20
Fuel Pump Module LG At Fuel Tank N/S
Generator BK Left Front Side of Engine 20
Glow Plug Assembly (Diesel) Top of Engine N/S
Headlamp Leveling Switch (BUX) BK Center of Instrument Panel N/S
Heated Seat Module (Highline) GN At Left Seat N/S
High Note Horn BK Left Front Side of Engine
Compartment29
Hood Ajar Switch Right Side of Engine
Compartment25
Idle Air Control Motor BK On Throttle Body 1
Ignition Switch At Steering Column N/S
Input Speed Sensor (3.7L) BK Left Side of Transmission 5
Instrument Cluster BK Rear of Cluster N/S
Intake Air Temperature Sensor GY Left Side of Intake Manifold 1
Intrusion Sensor (BUX) BK Overhead Console N/S
Junction Block Body Control Module -
JBUnder Left Side of
Instrument PanelN/S
Junction Block C1 GY Under Left Side of
Instrument PanelN/S
Junction Block C2 GN Under Left Side of
Instrument PanelN/S
Junction Block C3 LB Under Left Side of
Instrument PanelN/S
Knock Sensor (3.7L) BK Near Fuel Injector No.5 1
Leak Detection Pump BK Near Fuel Tank N/S
Left Curtain Airbag YL Left Mid B-Pillar 35, 38
Left Cylinder Lock Switch LG In Left Front Door 41
Left Door Lock Switch BK In Left Front Door 41
Left Fog Lamp BK Left Side of Front Bumper N/S
KJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION8Wa-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

GROUND NUMBER LOCATION FIG.
G201 Under Center Console 33, 37
G202 Left Kick Panel (Black Connector) N/S
G203 Under Center of Instrument Panel N/S
G300 Left Front Seat 35
G301 Under Center Console N/S
G302 Right Front Seat 39
G310 Right Quarter Panel 44, 45
G311 Left Quarter Panel 43
G312 Left Quarter Panel N/S
G320 At Fuel Tank N/S
SPLICES
SPLICE NUMBER LOCATION FIG.
S101 Near T/O to Power Distribution Center N/S
S104 Near T/O to Power Distribution Center N/S
S106 Near T/O for G112 N/S
S107 (Diesel) In T/O for C100 32
S108 Near T/O for C106 29
S109 In Trough Near T/O for Radiator Fan Relay N/S
S110 Near T/O for C106 29
S111 In Trough Near T/O for Radiator Fan Relay N/S
S112 Near T/O to Power Distribution Center N/S
S113 (LHD) In T/O for C100 32
S114 In T/O for C100 N/S
S115 Near T/O for Engine Control Module N/S
S118 In T/O for C100 32
S121 Near T/O to Power Distribution Center N/S
S122 In T/O for Controller Antilock Brake 30
S123 In Trough, Front of Engine Compartment N/S
S124 In T/O for Junction Block C3 N/S
S125 In T/O for Junction Block C3 N/S
S130 Near T/O for Left Headlamp N/S
S131 In T/O for Right Headlamp N/S
S140 Near T/O for Left Front Park/Turn Signal Lamp N/S
S141 Near T/O for Left Fog Lamp N/S
S142 Near T/O for Left Front Park/Turn Signal Lamp N/S
S143 Near T/O for Right Front Park/Turn Signal Lamp N/S
S144 Near T/O for Left Fog Lamp N/S
S145 Near T/O for Right Front Park/Turn Signal Lamp N/S
S146 Near T/O for Right Front Park/Turn Signal Lamp N/S
S151 (2.4L) Near T/O for C110 11, 12
S151 (3.7L) In Trough Near T/O for Fuel Injector No.3 1
8Wa - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONKJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

ENGINE BLOCK
DESCRIPTION.........................39
STANDARD PROCEDURE - CYLINDER BORE
HONING............................39
CLEANING............................39
INSPECTION..........................40
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING - FITTING...............40
CRANKSHAFT
DESCRIPTION.........................42
REMOVAL.............................43
INSPECTION..........................43
INSTALLATION.........................43
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING - FITTING...............45
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................46
INSTALLATION.........................47
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................48
INSTALLATION.........................48
FLEX PLATE
REMOVAL.............................49
INSTALLATION.........................49
PISTON & CONNECTING ROD
DESCRIPTION.........................49
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING . . . 49
STANDARD PROCEDURE - PISTON
FITTING.............................50
REMOVAL.............................50
CLEANING............................51
INSPECTION..........................51
INSTALLATION.........................51
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING.............................52
VIBRATION DAMPER
REMOVAL.............................54
INSTALLATION.........................55
STRUCTURAL COVER
DESCRIPTION.........................55
OPERATION...........................55
REMOVAL.............................55
INSTALLATION.........................55
FRONT MOUNT
REMOVAL.............................56
INSTALLATION.........................57
REAR MOUNT
REMOVAL.............................57
INSTALLATION.........................57
LUBRICATION
DESCRIPTION.........................57
OPERATION...........................58DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK...............................60
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE..........................60
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS.........................61
OIL
STANDARD PROCEDURE - ENGINE OIL.....61
OIL FILTER
REMOVAL.............................63
INSTALLATION.........................63
OIL PAN
DESCRIPTION.........................63
REMOVAL.............................63
CLEANING............................63
INSPECTION..........................63
INSTALLATION.........................64
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................65
OPERATION...........................65
REMOVAL.............................65
INSTALLATION.........................65
OIL PUMP
REMOVAL.............................65
DISASSEMBLY.........................65
INSPECTION..........................66
ASSEMBLY............................67
INSTALLATION.........................67
INTAKE MANIFOLD
DESCRIPTION.........................68
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................68
REMOVAL.............................68
INSTALLATION.........................69
EXHAUST MANIFOLD
DESCRIPTION.........................69
REMOVAL.............................69
INSTALLATION.........................70
VALVE TIMING
DESCRIPTION.........................71
OPERATION...........................71
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR.......71
SERVICE PROCEDURES...............72
BALANCE SHAFT
REMOVAL.............................74
INSTALLATION.........................74
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................74
INSTALLATION.........................76
IDLER SHAFT
REMOVAL.............................77
INSTALLATION.........................77
TIMING BELT/CHAIN AND SPROCKET(S
REMOVAL.............................77
INSPECTION..........................79
INSTALLATION.........................80
9 - 2 ENGINE - 3.7LKJ