torque JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

DIAGNOSIS AND TESTING - REAR SEAL AREA
LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, camshaft bore
cup plugs, oil galley pipe plugs, oil filter runoff,
and main bearing cap to cylinder block mating sur-
faces. See Engine, for proper repair procedures of
these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the section, Inspection (Engine oil
Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING), under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
OIL
STANDARD PROCEDURE - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
Fig. 70 Oil Pressure Sending Unit -Typical
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
KJENGINE - 3.7L 9 - 61
LUBRICATION (Continued)

INTAKE MANIFOLD
DESCRIPTION
The intake manifold (Fig. 86) is made of a compos-
ite material and features 300 mm (11.811 in.) long
runners which maximizes low end torque. The intake
manifold uses single plane sealing which consist of
six individual press in place port gaskets to prevent
leaks. The throttle body attaches directly to the
intake manifold. Eight studs and two bolts are used
to fasten the intake to the head.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect throttle and speed control cables.
(4) Disconnect electrical connectors for the follow-
ing components: Refer to FUEL SYSTEM for compo-
nent locations.
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Disconnect vapor purge hose, brake booster
hose, speed control servo hose, positive crankcase
ventilation (PCV) hose.
(6) Disconnect generator electrical connections.
(7) Disconnect air conditioning compressor electri-
cal connections.
(8) Disconnect left and right radio suppressor
straps.
(9) Disconnect and remove ignition coil towers.
(10) Remove top oil dipstick tube retaining bolt
and ground strap.
Fig. 85 Oil Pump and Primary Timing Chain
Tensioner Tightening Sequence
Fig. 86 INTAKE MANIFOLD
1 - THROTTLE BODY
2 - INTAKE MANIFOLD
3 - INTAKE PORT GASKETS
9 - 68 ENGINE - 3.7LKJ
OIL PUMP (Continued)

(11) Bleed fuel system. Refer to FUEL SYSTEM.
(12) Remove fuel rail.
(13) Remove throttle body assembly and mounting
bracket.
(14) Drain cooling system below coolant tempera-
ture level. Refer to COOLING SYSTEM.
(15) Remove the heater hoses from the engine
front cover and the heater core.
(16) Unclip and remove heater hoses and tubes
from intake manifold.
(17) Remove coolant temperature sensor. Refer to
FUEL SYSTEM.
(18) Remove intake manifold retaining fasteners in
reverse order of tightening sequence.
(19) Remove intake manifold.
INSTALLATION
(1) Install intake manifold gaskets.
(2) Install intake manifold.
(3) Install intake manifold retaining bolts and
tighten in sequence shown in to 12 N´m (105 in. lbs.).
(4) Install left and right radio suppressor straps.
(5) Install throttle body assembly.
(6) Install throttle cable bracket.
(7) Connect throttle cable and speed control cable
to throttle body.
(8) Install fuel rail.
(9) Install ignition coil towers.
(10) Position and install heater hoses and tubes
onto intake manifold.
(11) Install the heater hoses to the heater core and
engine front cover.
(12) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
²Ignition coil towers
²Fuel injectors
(13) Install top oil dipstick tube retaining bolt and
ground strap.
(14) Connect generator electrical connections.
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Positive crankcase
ventilation (PCV) hose.
(16) Fill cooling system.
(17) Install resonator assembly and air inlet hose.
(18) Connect negative cable to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 87) are log style with
a patented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high sili-
con molybdenum cast iron. A perforated core graphite
exhaust manifold gasket is used to improve sealing
to the cylinder head. The exhaust manifolds are cov-
ered by a three layer laminated heat shield for ther-
mal protection and noise reduction. The heat shields
(Fig. 88) are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
REMOVAL
RIGHT EXHAUST MANIFOLD
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle.
(5) Remove the exhaust heat shield (Fig. 89).
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold and gasket from the cylinder
head.
Fig. 87 EXHAUST MANIFOLDS
1 - LEFT SIDE EXHAUST MANIFOLD
2 - RIGHT SIDE EXHAUST MANIFOLD
KJENGINE - 3.7L 9 - 69
INTAKE MANIFOLD (Continued)

(1) Position the engine exhaust manifold and gas-
ket on the two studs located on the cylinder head.
Install conical washers and nuts on these studs.
(2) Install remaining conical washers. Starting at
the center arm and working outward, tighten the
bolts and nuts to 25 N´m (18 ft. lbs.) torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
LEFT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Position the engine exhaust manifold and gas-
ket on the two studs located on the cylinder head.
Install conical washers and nuts on these studs.
(2) Install remaining conical washers. Starting at
the center arm and working outward, tighten the
bolts and nuts to 25 N´m (18 ft. lbs.) torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
VALVE TIMING
DESCRIPTION
The timing drive system has been designed to pro-
vide quiet performance and reliability to support a
non-free wheelingengine. Specifically the intake
valves are non-free wheeling and can be easily dam-
aged with forceful engine rotation if camshaft-to-
crankshaft timing is incorrect. The timing drive
system consists of a primary chain, two secondary
timing chain drives and a counterbalance shaft drive.
OPERATION
The primary timing chain is a single inverted tooth
chain type. The primary chain drives the large 40
tooth idler sprocket directly from a 20 tooth crank-shaft sprocket. Primary chain motion is controlled by
a pivoting leaf spring tensioner arm and a fixed
guide. The arm and the guide both use nylon plastic
wear faces for low friction and long wear. The pri-
mary chain receives oil splash lubrication from the
secondary chain drive and designed oil pump leak-
age. The idler sprocket assembly connects the pri-
mary chain drive, secondary chain drives, and the
counterbalance shaft. The idler sprocket assembly
consists of two integral 26 tooth sprockets a 40 tooth
sprocket and a helical gear that is press-fit to the
assembly. The spline joint for the 40 tooth sprocket is
a non ± serviceable press fit anti rattle type. A spiral
ring is installed on the outboard side of the fifty
tooth sprocket to prevent spline disengagement. The
idler sprocket assembly spins on a stationary idler
shaft. The idler shaft is a light press-fit into the cyl-
inder block. A large washer on the idler shaft bolt
and the rear flange of the idler shaft are used to con-
trol sprocket thrust movement. Pressurized oil is
routed through the center of the idler shaft to pro-
vide lubrication for the two bushings used in the
idler sprocket assembly.
There are two secondary drive chains, both are
roller type, one to drive the camshaft in each SOHC
cylinder head. There are no shaft speed changes in
the secondary chain drive system. Each secondary
chain drives a 26 tooth cam sprocket directly from
the 26 tooth sprocket on the idler sprocket assembly.
A fixed chain guide and a hydraulic oil damped ten-
sioner are used to maintain tension in each second-
ary chain system. The hydraulic tensioners for the
secondary chain systems are fed pressurized oil from
oil reservoir pockets in the block. Each tensioner
incorprates a controled leak path through a device
known as a vent disc located in the nose of the piston
to manage chain loads. Each tensioner also has a
mechanical ratchet system that limits chain slack if
the tensioner piston bleeds down after engine shut
down. The tensioner arms and guides also utilize
nylon wear faces for low friction and long wear. The
secondary timing chains receive lubrication from a
small orifice in the tensioners. This orifice is pro-
tected from clogging by a fine mesh screen which is
located on the back of the hydraulic tensioners.
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the timing chain cover. Refer to Timing
Chain Cover in this section for procedure.
KJENGINE - 3.7L 9 - 71
EXHAUST MANIFOLD (Continued)

(5) Using Special Tool 8428 Camshaft Wrench,
rotate the camshaft until the alignment dowel on the
camshaft is aligned with the slot in the camshaft
drive gear.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(6) Position the camshaft drive gear onto the cam-
shaft, remove oil from bolt then install the retaining
bolt. Using Special Tools, Spanner Wrench 6958 with
Adapter Pins 8346 and a suitable torque wrench,
Tighten retaining bolt to 122N´m (90 ft. Lbs.).
(7) Remove Special Tool 8379.
(8) Rotate the crankshaft two full revolutions, then
reverify that the camshaft drive gear V6 marks are
in fact aligned.
(9) Install the cylinder head covers. Refer to Cylin-
der Head Cover in this section.
Fig. 92 COUNTERBALANCE SHAFT ALIGNMENT
MARKS
1 - COUNTERBALANCE SHAFT
2 - TIMING MARKS
3 - IDLER SPROCKET
Fig. 93 SECURING TIMING CHAIN TENSIONER
USING TIMING CHAIN WEDGE
1 - CYLINDER HEAD
2 -SPECIAL TOOL 8379
2 - TIMING CHAIN
Fig. 94 CAMSHAFT DRIVE GEAR REMOVAL/INST
1 - SPECIAL TOOL 8279 TIMING CHAIN WEDGE
2 - CAMSHAFT DRIVE GEAR
3 - RETAINING BOLT
4 - CYLINDER HEAD
KJENGINE - 3.7L 9 - 73
VALVE TIMING (Continued)

BALANCE SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains. Refer to TIMING CHAIN and SPROCKET.
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.Remove the retaining bolt
from the counterbalance shaft thrust plate (Fig. 96).
(2) Using Special Tool 8641 Counterbalance shaft
remover/installer tool, remove the counterbalance
shaft from the engine (Fig. 97).
INSTALLATION
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.
(1) Coat counterbalance shaft bearing journals
with clean engine oil.
NOTE: The balance shaft is heavy, and care should
be used when installing shaft, so bearings are not
damaged.(2) Using Special Tool 8641 Counterbalance shaft
remover/installer tool, carefully install counterbal-
ance shaft into engine.
(3) Install Counterbalance shaft thrust plate
retaining bolt finger tight.Do not tighten bolt at this
time.
(4) Position the right side of the thrust plate with
the right chain guide bolt, install bolt finger tight.
(5) Torque the thrust plate retaining bolt to 28
N´m (250 in. lbs.).
(6) Remove the chain guide bolt so that guide can
be installed.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove electric cooling fan and fan shroud
assembly.
(4) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(5) Disconnect both heater hoses at timing cover.
(6) Disconnect lower radiator hose at engine.
Fig. 95 Camshaft Sprocket V6 Marks
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
9 - 74 ENGINE - 3.7LKJ
VALVE TIMING (Continued)

IDLER SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains and sprockets. Refer to procedure in this sec-
tion.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore.
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil.
(5) Install the timing chains and sprockets. Refer
to procedure in this section.
TIMING BELT/CHAIN AND
SPROCKET(S
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to COOLING SYS-
TEM for procedures.
(3) Remove right and left cylinder head covers.
Refer to CYLINDER HEAD COVER.
(4) Remove radiator fan shroud. Refer to COOL-
ING SYSTEM for procedure.
(5) Rotate engine until timing mark on crankshaft
damper aligns with TDC mark on timing chain cover
(Fig. 103) (#1 cylinder exhaust stroke) and the cam-
shaft sprocket ªV6º marks are at the 12 o'clock posi-
tion (Fig. 102).
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed
retorque nut to 5 N´m (44 in. lbs.).
(6) Remove power steering pump. Refer to STEER-
ING for procedure.
(7) Remove access plug from left and right cylinder
heads for access to chain guide fasteners (Fig. 104).
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper and timing chain
cover. Refer to procedures.
(10) Collapse and pin primary chain tensioner.
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chain tensioners.
(12) Remove camshaft position and crankshaft
position sensors (Fig. 105) and (Fig. 106).
KJENGINE - 3.7L 9 - 77

NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Align left camshaft sprocket ªLº dot to plated
link on chain.
(12) Align right camshaft sprocket ªRº dot to
plated link on chain.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
(13) Remove Special Tool 8429, then attach both
sprockets to camshafts. Remove excess oil from bolts,
then Install sprocket bolts, but do not tighten at this
time.
(14) Verify that all plated links are aligned with
the marks on all sprockets and the ªV6º marks on
camshaft sprockets are at the 12 o'clock position.
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) Install both secondary chain tensioners.
Tighten bolts to 28 N´m (250 in. lbs.).
NOTE: Left and right secondary chain tensioners
are not common.(16) Remove all locking pins (3) from tensioners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(17) Using Special Tool 6958, Spanner with Adap-
tor Pins 8346, tighten left (Fig. 110) and right (Fig.
111). camshaft sprocket bolts to 122 N´m (90 ft. lbs.).
(18) Rotate engine two full revolutions. Verify tim-
ing marks are at the follow locations:
²primary chain idler sprocket dot is at 12 o'clock
²primary chain crankshaft sprocket dot is at 6
o'clock
²secondary chain camshaft sprockets ªV6º marks
are at 12 o'clock
²counterbalancer shaft drive gear dot is aligned
to the idler sprocket gear dot
(19) Lubricate all three chains with engine oil.
Fig. 109 COUNTERBALANCE SHAFT ALIGNMENT
MARKS
1 - COUNTERBALANCE SHAFT
2 - TIMING MARKS
3 - IDLER SPROCKET
Fig. 110 Tightening Left Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
3 - LEFT CYLINDER HEAD
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
KJENGINE - 3.7L 9 - 81
TIMING BELT/CHAIN AND SPROCKET(S (Continued)

(20) After installing all chains, it is recommended
that the idler gear end play be checked (Fig. 112).
The end play must be within 0.10±0.25 mm (0.004±
0.010 in.). If not within specification, the idler gear
must be replaced.
(21) Install timing chain cover and crankshaft
damper. Refer to procedures.
(22) Install cylinder head covers. Refer to proce-
dures.
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.(23) Coat the large threaded access plug with
MopartThread Sealant with Teflon, then install
into the right cylinder head and tighten to 81 N´m
(60 ft. lbs.).
(24) Install the oil fill housing.
(25) Install access plug in left cylinder head.
(26) Install power steering pump.
(27) Fill cooling system.
(28) Connect negative cable to battery.
Fig. 111 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKETFig. 112 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
9 - 82 ENGINE - 3.7LKJ
TIMING BELT/CHAIN AND SPROCKET(S (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE - 2.4L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST................................3
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST.........3
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION.....................4
DIAGNOSIS AND TESTING - ENGINE.......5
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............5
DIAGNOSIS AND TESTING - ENGINE
MECHANICAL.........................7
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS...............9
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS..........9
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE......................9
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........10
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........11
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE.........................11
REMOVAL - ENGINE ASSEMBLY...........12
INSTALLATION - ENGINE ASSEMBLY........12
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE.........13
SPECIFICATIONS - TORQUE............16
SPECIAL TOOLS
2.4L ENGINE.........................17
AIR CLEANER ELEMENT
REMOVAL - 2.4L........................19
INSTALLATION - 2.4L....................19
CYLINDER HEAD
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET............................19
REMOVAL - CYLINDER HEAD.............20
CLEANING............................20
INSPECTION..........................21
INSTALLATION - CYLINDER HEAD..........21CAMSHAFT OIL SEAL(S)
REMOVAL.............................22
INSTALLATION.........................22
CAMSHAFT(S)
DESCRIPTION.........................23
OPERATION...........................23
STANDARD PROCEDURE - CAMSHAFT
END-PLAY...........................23
REMOVAL.............................24
CLEANING............................24
INSPECTION..........................25
INSTALLATION.........................25
CYLINDER HEAD COVER
REMOVAL.............................26
CLEANING............................26
INSPECTION..........................26
INSTALLATION.........................26
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................27
CLEANING............................27
VALVE SPRINGS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........27
REMOVAL - CYLINDER HEAD OFF........27
INSPECTION..........................28
INSTALLATION
INSTALLATION - CYLINDER HEAD ON.....28
INSTALLATION - CYLINDER HEAD OFF....28
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING - LASH ADJUSTER
(TAPPET) NOISE DIAGNOSIS............28
REMOVAL.............................29
INSTALLATION.........................29
ROCKER ARMS
REMOVAL.............................29
INSPECTION..........................30
INSTALLATION.........................30
ENGINE BLOCK
DESCRIPTION.........................30
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING..............30
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................31
CLEANING............................31
INSPECTION..........................32
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING...........32
KJENGINE 9s - 1