clock JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(19) Disconnect test leads from relay cavities
immediately after testing.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module assembly is located in the
fuel tank (Fig. 1). The assembly is divided into 2±sec-
tions, upper and lower. The lower section is locked to
the bottom of the fuel tank. The complete assembly
contains the following components:
²A fuel pressure regulator
²A separate fuel pick-up, or inlet filter
²An electric fuel pump
²A lockring to retain upper section of pump mod-
ule to tank
²A rollover valve
²A vent fitting for ORVR system
²A soft gasket between tank flange and module
²A fuel gauge sending unit (fuel level sensor)
²Two fuel line connections (supply and return)
The fuel gauge sending unit may be serviced sepa-
rately. If the electrical fuel pump, primary inlet filter
or fuel pressure regulator require service, the lower
section of the fuel pump module must be replaced.
OPERATION
Refer to Fuel Pump, Inlet Filter, Fuel Pressure
Regulator and Fuel Gauge Sending Unit.
REMOVAL
The fuel pump module is divided into 2 sections,
upper and lower. To service the check (control) valve,
replace only the upper section. To service the fuel
gauge sending unit, remove the upper section. To ser-
vice the electric fuel pump, fuel pressure regulator or
primary inlet filter, remove both sections and replace
lower section.
Fuel tank removal will not be necessary for
fuel pump module removal. Access is from rear
cargo area.
(1) Four cargo holdown clamps are located inside
the vehicle on the floor of the rear cargo area.Remove the 2 rearward mounted clamps by drilling
out the clamp rivets.
(2) Fold carpeting forward to gain access to fuel
pump module access plate (Fig. 25).
(3) Remove 4 fuel pump module access plate nuts
(Fig. 25).
(4) While applying heat from a heat gun, carefully
pry up fuel pump module access plate. Take care not
to bend plate.
(5) Thoroughly clean area around top of pump
module to prevent contaminants from entering fuel
tank or fuel lines.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
(6) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure.
(7) Disconnect 2 fuel lines at fuel pump module
(Fig. 26) by pressing on 2 buttons at sides of fitting.
(8) Disconnect electrical connector (Fig. 26) at top
of fuel pump module by sliding red colored tab first
to unlock, and push grey colored tab down for
removal.
(9) Disconnect ORVR hose clamp and hose (Fig.
26) at pump module fitting.
(10) Remove module lockring (Fig. 26) using a
brass drift and hammer (counter-clockwise).
(11) Carefully lift upper section of pump module
(Fig. 26) from fuel tank exposing connections(lift
upper section from tank very slowly until rub-
ber gasket can be retained. If not, gasket will
fall into fuel tank.)
(a) Disconnect electrical connector (Fig. 27) at
bottom of upper pump module section.
(b) Disconnect fuel pressure regulator (Fig. 27)
at bottom of upper pump module section. Press on
2 locking tabs.
(c) Disconnect fuel return line (Fig. 27) at bot-
tom of upper pump module section. Press on 2
locking tabs.
(d) Remove upper section of pump module (Fig.
28) from fuel tank.
(12) Using an approved gas holding tank, drain
fuel tank through pump module opening.If check
(control) valve, or, only upper section of pump
module is being serviced, tank draining is not
necessary. If any other fuel pump module com-
ponent is being serviced, the tank must be com-
pletely drained to the bottom.
(13) To remove lower section of pump module from
fuel tank:
(a) Using finger pressure, push on plastic
release tab (Fig. 29) while sliding lock tab upward.
14 - 18 FUEL DELIVERYKJ
FUEL PUMP (Continued)

(b) The sides of pump module are equipped with
tension springs (Fig. 29). These springs hold mod-
ule to bottom of fuel tank into 2 formed guides
(Fig. 30). Release module assembly from these 2
guides by sliding toward right side of fuel tank.
(c) Lift assembly from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
pump module gasket must be replaced.
(1) Position lower section of fuel pump module
assembly into fuel tank.
(2) The bottom of fuel tank has 2 formed guides.
Lock module assembly into these 2 guides by sliding
toward left side of fuel tank.
(3) Push down on plastic tab to lock module to fuel
tank guides.
(4) Connect fuel supply line to bottom of upper
pump module section.
(5) Connect fuel pressure regulator to bottom of
upper pump module section.
(6) Connect electrical connector to bottom of upper
pump module section.
(7) Position pump module into fuel tank. Notch on
module must be facing rear of tank.(8) Position lock ring to module. Tap lockring
using a brass drift and hammer (clockwise) until
rotated up to built-on stops.
(9) Attach (snap on) 2 fuel filter fuel lines to top of
fuel pump module.
(10) Connect hoses/lines to ORVR components.
(11) Fill fuel tank with fuel.
(12) Start engine and check for fuel leaks.
(13) Apply silicone sealant to bottom of fuel pump
module metal access plate.
(14) Install fuel pump module metal access plate
and 4 nuts. Tighten nuts to 3 N´m (26 in. lbs.)
torque.
(15) Position carpet and install 2 new cargo clamp
rivets into each cargo holdown clamp.
Fig. 25 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
Fig. 26 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)
KJFUEL DELIVERY 14 - 19
FUEL PUMP MODULE (Continued)

(11) Remove module lockring (Fig. 40) using a
brass drift and hammer (counter-clockwise).
(12) Carefully lift upper section of pump module
from fuel tank a few inches(lift upper section
from tank very slowly until rubber gasket can
be retained. If not, gasket will fall into fuel
tank).
(13) Using an approved gas holding tank, drain
fuel tank through fuel pump module opening.
Tank Removal
(1) After draining tank, temporarily place upper
section of fuel pump module back into fuel tank.
(2) Raise vehicle.
(3) If equipped, remove fuel tank skid plate and
tow hooks. Certain equipment packages will also
require removal of the trailer hitch. Refer to Tow
Hooks, Trailer Hitch or Skid Plate in 23, Body for
removal/installation procedures.
(4) Disconnect fuel filter ground strap.
(5) Disconnect fuel filter outlet line from body
retention clip located on frame near front/center of
tank (Fig. 41). Place a small screwdriver into side of
clip and twist for removal. Also disconnect Leak
Detection Pump (LDP) line (Fig. 41) from this clip.(6) Remove both 3/4º hoses at sides of Leak Detec-
tion Pump (LDP) (Fig. 41).
(7) Disconnect 3/4º flow management valve hose
(Fig. 41) at EVAP canister.
(8) Remove fuel fill hose clamp (Fig. 42) at fuel
tank, and disconnect hose from fuel tank.
(9) A third fuel line is attached to bottom of fuel
filter. The disconnection point (quick-connect fitting)
for this 3rd line is approximately 1 foot from front of
tank towards front of vehicle (Fig. 41). Clean connec-
tion point before disconnection. Disconnect by press-
ing on tabs at side of quick-connect fitting. Also
disconnect LDP vent line near this same point.
(10) Disconnect 2 vacuum/vent hoses from plastic
retention clip at left/front of fuel tank line (Fig. 41).
(11) Support tank with a hydraulic jack.
(12) Remove 4 fuel tank strap bolts (Fig. 41) (2 at
front of tank; 2 at rear of tank), and remove both
tank support straps (Fig. 41).
(13) Carefully lower tank a few inches and discon-
nect electrical connector at top of LDP (Fig. 43). To
disconnect electrical connector: Push upward on red
colored tab to unlock. Push on black colored tab
while removing connector.
Fig. 40 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)Fig. 41 FRONT OF FUEL TANK
1 - TANK MOUNTING BOLTS (4)
2 - TANK MOUNTING STRAPS (2)
3 - LEAK DETECTION PUMP (LDP)
4 - BODY RETENTION CLIP (CENTER)
5 - LDP HOSES
6 - HOSE TO FUEL MANAGEMENT VALVE
7 - BODY RETENTION CLIP (LEFT/FRONT)
8 - QUICK-CONECT FITTING
9 - LDP LINE
14 - 26 FUEL DELIVERYKJ
FUEL TANK (Continued)

The resistance values of the IAT sensor is the same
as for the Engine Coolant Temperature (ECT) sensor.
REMOVAL
2.4L
The intake manifold air temperature (IAT) sensor
is installed into the intake manifold plenum at the
rear end of the intake manifold (Fig. 14).
(1) Disconnect electrical connector from IAT sen-
sor.
(2) Clean dirt from intake manifold at sensor base.
(3) Gently lift on small plastic release tab (Fig. 14)
or (Fig. 15) and rotate sensor about 1/4 turn counter-
clockwise for removal.
(4) Check condition of sensor o-ring (Fig. 15).
3.7L
The intake manifold air temperature (IAT) sensor
is installed into the left side of intake manifold ple-
num (Fig. 16).
(1) Disconnect electrical connector from IAT sen-
sor.
(2) Clean dirt from intake manifold at sensor base.
(3) Gently lift on small plastic release tab (Fig. 16)
or (Fig. 15) and rotate sensor about 1/4 turn counter-
clockwise for removal.
(4) Check condition of sensor o-ring.
Fig. 14 IAT SENSOR LOCATION-2.4L
1 - RELEASE TAB
2 - IAT SENSOR
3 - PRESS HERE FOR REMOVAL
4 - ELECTRICAL CONNECTOR
5 - REAR END OF INTAKE MANIFOLD
Fig. 15 IAT SENSOR TAB / O-RING
1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
Fig. 16 IAT SENSOR LOCATION- 3.7L
1 - IAT SENSOR
2 - RELEASE TAB
3 - ELECTRICAL CONNECTOR
KJFUEL INJECTION 14 - 37
INTAKE AIR TEMPERATURE SENSOR (Continued)

INSTALLATION
2.4L
The intake manifold air temperature (IAT) sensor
is installed into the intake manifold plenum at the
rear end of the intake manifold.
(1) Check condition of sensor o-ring.
(2) Clean sensor mounting hole in intake manifold.
(3) Position sensor into intake manifold and rotate
clockwise until past release tab.
(4) Install electrical connector.
3.7L
The intake manifold air temperature (IAT) sensor
is installed into the left side of intake manifold ple-
num (Fig. 16).
(1) Check condition of sensor o-ring.
(2) Clean sensor mounting hole in intake manifold.
(3) Position sensor into intake manifold and rotate
clockwise until past release tab (Fig. 16).
(4) Install electrical connector.
MAP SENSOR
DESCRIPTION
2.4L
The Manifold Absolute Pressure (MAP) sensor is
mounted into the rear of the intake manifold with 1
screw.
3.7L
The Manifold Absolute Pressure (MAP) sensor is
mounted into the front of the intake manifold with 2
screws.
OPERATION
The MAP sensor is used as an input to the Power-
train Control Module (PCM). It contains a silicon
based sensing unit to provide data on the manifold
vacuum that draws the air/fuel mixture into the com-
bustion chamber. The PCM requires this information
to determine injector pulse width and spark advance.
When manifold absolute pressure (MAP) equals
Barometric pressure, the pulse width will be at max-
imum.
A 5 volt reference is supplied from the PCM and
returns a voltage signal to the PCM that reflects
manifold pressure. The zero pressure reading is 0.5V
and full scale is 4.5V. For a pressure swing of 0±15
psi, the voltage changes 4.0V. To operate the sensor,
it is supplied a regulated 4.8 to 5.1 volts. Ground is
provided through the low-noise, sensor return circuit
at the PCM.The MAP sensor input is the number one contrib-
utor to fuel injector pulse width. The most important
function of the MAP sensor is to determine baromet-
ric pressure. The PCM needs to know if the vehicle is
at sea level or at a higher altitude, because the air
density changes with altitude. It will also help to cor-
rect for varying barometric pressure. Barometric
pressure and altitude have a direct inverse correla-
tion; as altitude goes up, barometric goes down. At
key-on, the PCM powers up and looks at MAP volt-
age, and based upon the voltage it sees, it knows the
current barometric pressure (relative to altitude).
Once the engine starts, the PCM looks at the voltage
again, continuously every 12 milliseconds, and com-
pares the current voltage to what it was at key-on.
The difference between current voltage and what it
was at key-on, is manifold vacuum.
During key-on (engine not running) the sensor
reads (updates) barometric pressure. A normal range
can be obtained by monitoring a known good sensor.
As the altitude increases, the air becomes thinner
(less oxygen). If a vehicle is started and driven to a
very different altitude than where it was at key-on,
the barometric pressure needs to be updated. Any
time the PCM sees Wide Open Throttle (WOT), based
upon Throttle Position Sensor (TPS) angle and RPM,
it will update barometric pressure in the MAP mem-
ory cell. With periodic updates, the PCM can make
its calculations more effectively.
The PCM uses the MAP sensor input to aid in cal-
culating the following:
²Manifold pressure
²Barometric pressure
²Engine load
²Injector pulse-width
²Spark-advance programs
²Shift-point strategies (certain automatic trans-
missions only)
²Idle speed
²Decel fuel shutoff
The MAP sensor signal is provided from a single
piezoresistive element located in the center of a dia-
phragm. The element and diaphragm are both made
of silicone. As manifold pressure changes, the dia-
phragm moves causing the element to deflect, which
stresses the silicone. When silicone is exposed to
stress, its resistance changes. As manifold vacuum
increases, the MAP sensor input voltage decreases
proportionally. The sensor also contains electronics
that condition the signal and provide temperature
compensation.
The PCM recognizes a decrease in manifold pres-
sure by monitoring a decrease in voltage from the
reading stored in the barometric pressure memory
cell. The MAP sensor is a linear sensor; meaning as
pressure changes, voltage changes proportionately.
14 - 38 FUEL INJECTIONKJ
INTAKE AIR TEMPERATURE SENSOR (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................5
OPERATION - SERVICE PRECAUTIONS......5
REMOVAL.............................5
INSTALLATION..........................7
SPECIFICATIONS
TORQUE CHART......................8
SPECIAL TOOLS
STEERING COLUMN....................8
IGNITION SWITCH
DESCRIPTION..........................8
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................8
REMOVAL
IGNITION SWITCH REMOVAL.............9INSTALLATION
IGNITION SWITCH INSTALLATION.........9
KEY-IN IGNITION SWITCH
DESCRIPTION.........................10
DIAGNOSIS AND TESTING - KEY-IN IGNITION
SWITCH............................10
LOCK CYLINDER
REMOVAL.............................10
INSTALLATION.........................11
INTERMEDIATE SHAFT
REMOVAL.............................11
INSTALLATION.........................11
STEERING WHEEL
REMOVAL.............................12
INSTALLATION.........................12
COLUMN
DESCRIPTION
The standard non-tilt and tilt steering column has
been designed to be serviced as an assembly. The col-
umn is connected to the steering gear with a one
piece shaft. The upper half has a support bearing
mounted to a bracket. The bracket mounts to the
frame rail with two nuts. The shaft is serviceable.
The key cylinder, switches, clock spring, trim shrouds
and steering wheel are serviced separately.
OPERATION - SERVICE PRECAUTIONS
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag,
refer to Electrical - Restraints and follow all WARN-
INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWOMINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.REMOVAL
(1) Position front wheelsstraight ahead.
(2) Remove and isolate the negative ground cable
from the battery.
(3) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
NOTE: If equipped with cruise control, disconnect
clock spring harness from the cruise switch har-
ness on the steering wheel.
KJCOLUMN 19 - 5

(4) Remove the steering wheel with an appropriate
puller (Fig. 1) (Refer to 19 - STEERING/COLUMN/
STEERING WHEEL - REMOVAL).
(5) Remove knee blocker cover and knee blocker,
(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL). (Fig. 2)
(6) Remove screws from the lower column shroud
(Fig. 3) and remove both the upper and lower
shrouds.
(7) Turn ignition key to the on position.(8) If vehicle is equipped with automatic transmis-
sion, disconnect shifter interlock cable from the col-
umn.
(9) Remove the steering coupler bolt and column
mounting nuts and bolts (Fig. 4) then lower column
off the mounting studs.
(10) Disconnect and remove the wiring harness
from the column (Fig. 5).
(11) Slide the shifter interlock cable from the tie
straps.
(12) Remove column.
(13) Transfer the necessary parts if needed.
(14) Remove clock spring (Fig. 6), switches, (SKIM
if equipped) (Refer to 8 - ELECTRICAL/RE-
STRAINTS/CLOCKSPRING - REMOVAL).
Fig. 1 Steering Wheel Puller
1 - PULLER C-3894-A
2 - STEERING WHEEL
Fig. 2 KNEE BLOCKER
Fig. 3 SHROUD REMOVAL/INSTALL
1 - Upper Shroud
2 - Lower Shroud
Fig. 4 STEERING COLUMN MOUNTING
1 - Steering Column
2 - Mounting Holes
19 - 6 COLUMNKJ
COLUMN (Continued)

INSTALLATION
(1) Align and install column into the steering cou-
pler.(2) Install column harness and connect harness to
switches.
(3) Reroute the shifter interlock cable through the
tie straps.
(4) Install the column onto the mounting studs.
(5) Install the two mounting nuts and the two
mounting bolts all finger tight.
CAUTION: Lower nuts must be installed and tight-
ened first then the upper nuts in order to prevent
damage to the capsules.
(6) Tighten the lower mounting nuts to 17 N´m
(150 in. lbs.).
(7) Tighten the upper mounting nuts to 17 N´m
(150 in. lbs.).
(8) Install the steering column coupler bolt and
tighten to 49 N´m (36 ft. lbs.).
(9) Reconnect the shifter interlock cable.
(10) Center the clock spring (if necessary) and
install it on the column, (Refer to 8 - ELECTRICAL/
RESTRAINTS/CLOCKSPRING - INSTALLATION).
(11) Snap together the column shrouds and install
the mounting screws.
(12) Install the knee blocker and the knee blocker
cover, (Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - INSTALLATION).
(13)
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.Install the
steering wheel and tighten bolt to 54 N´m (40 ft.
lbs.) (Refer to 19 - STEERING/COLUMN/STEERING
WHEEL - INSTALLATION).
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(14) Install the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(15) Install the negative battery terminal.
Fig. 5 WIRING HARNESS COLUMN
1 - Column Wiring Harness
2 - Multi-function Switch
3 - Ignition Switch
4 - Steering Column
Fig. 6 CLOCK SPRING
1 - Tilt Lever
2 - Ignition Switch
3 - Clockspring
4 - Steering Column
5 - SKIM
KJCOLUMN 19 - 7
COLUMN (Continued)

STEERING WHEEL
REMOVAL
(1) Disable and remove the drivers side airbag.(Re-
fer to 8 - ELECTRICAL/RESTRAINTS/DRIVER AIR-
BAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller C-3894±A or equivalent using the
top of the bolt to push on. (Fig. 13)
(4) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 54 N´m (40 ft. lbs.).
(3) Install the drivers side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 13 Steering Wheel Puller
1 - PULLER C-3894-A
2 - STEERING WHEEL
19 - 12 COLUMNKJ

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL
REMOVAL - 4WD......................13
REMOVAL - 2WD......................14
INSTALLATION
INSTALLATION - 4WD..................14INSTALLATION - 2WD..................14
SPECIFICATIONS
TORQUE CHART......................15
SPECIAL TOOLS
OUTER TIE ROD END REMOVAL TOOL....15
GEAR
DESCRIPTION
A rack and pinion steering gear (Fig. 1) is made up
of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
OPERATION
The steering column intermediate shaft is attached
to the gear pinion. The rotation of the pinion moves
the gear rack from side-to-side. This lateral action of
the rack pushes and pulls the tie rods, which are
connected to the steering knuckles to change the
direction of the front wheels.
REMOVAL
REMOVAL - 4WD
(1) Siphon the power steering fluid from the power
steering reservoir.
(2) Lock the steering wheel to prevent spinning of
the clockspring.
(3) Raise and support the vehicle.
(4) Remove the skid plate from under the front
end to gain access to the gear (Refer to 13 - FRAME
& BUMPERS/FRAME/FRONT SKID PLATE -
REMOVAL).
(5) Remove the front tire and wheel assemblies.
NOTE: Mark the alignment adjusting cams for eas-
ier installation.
(6) Remove the lower control arms. (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(7) Remove the front axle. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/FRONT AXLE - REMOV-
AL).
(8) Remove the tie rod end nuts.
(9) Separate tie rod ends from the knuckles with
Puller C-3894-A.
(10) Remove the intermediate shaft lower coupler
bolt and slide the coupler off the gear (Fig. 2).
(11) Remove power steering pressure hose bracket
(Fig. 3).
(12) Remove the power steering lines from the
gear (Fig. 2).
(13) Remove the mounting bolts from the gear to
the front cradle (Fig. 3).
(14) Remove the steering gear from the vehicle.
Fig. 1 Rack & Pinion Steering Gear
1 - TIE ROD - INNER
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER LH
4 - BOOTS
5 - TIE ROD END - OUTER RH
KJGEAR 19 - 13