Egr JEEP LIBERTY 2002 KJ / 1.G Workshop Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 2002, Model line: LIBERTY, Model: JEEP LIBERTY 2002 KJ / 1.GPages: 1803, PDF Size: 62.3 MB
Page 744 of 1803
(7) Reconnect the tailgate wire harness connector
for the flip-up glass ajar switch to the flip-up glass
latch connector receptacle.
(8) Reinstall the trim panel onto the tailgate inner
panel. (Refer to 23 - BODY/SWING GATE/TRIM
PANEL - INSTALLATION).
(9) From the outside of the tailgate, press the nut
cover firmly and evenly over the rear wiper motor
output shaft bezel using hand pressure until it snaps
into place.
(10) Reinstall the rear wiper arm onto the rear
wiper motor output shaft. (Refer to 8 - ELECTRI-
CAL/REAR WIPERS/WASHERS/REAR WIPER ARM
- INSTALLATION).
(11) Reconnect the battery negative cable.
REAR WIPER/WASHER
SWITCH
DESCRIPTION
The rear wiper and washer switches are integral to
the right (wiper) control stalk of the multi-function
switch. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/MULTI-FUNCTION SWITCH -
DESCRIPTION).
OPERATION
The rear wiper and washer switches are integral to
the right (wiper) control stalk of the multi-function
switch. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/MULTI-FUNCTION SWITCH -
OPERATION).
WIPER ARM PARK RAMP
REMOVAL
(1) Disengage the rear wiper arm support from the
wiper arm park ramp on the right side of the tailgate
just below the rear flip-up glass.(2) Lift the wiper arm and blade away from the
tailgate until the wiper arm hinge is in its over-cen-
ter position.
Remove the screw that secures the wiper arm park
ramp to the tailgate outer panel (Fig. 18).
(3) Remove the wiper arm park ramp from the
tailgate outer panel.
INSTALLATION
(1) Position the wiper arm park ramp onto the
tailgate outer panel (Fig. 18).
(2) Install and tighten the screw that secures the
wiper arm park ramp to the tailgate outer panel.
Tighten the screw to 5 N´m (45 in. lbs.).
(3) Lower the rear wiper arm and blade and place
the wiper arm support onto the wiper arm park
ramp.
Fig. 18 Wiper Arm Park Ramp Remove/Install
1 - SCREW (1)
2 - PARK RAMP
3 - RIVET NUT (1)
4 - TAILGATE OUTER PANEL
KJREAR WIPERS/WASHERS 8R - 43
REAR WIPER MOTOR (Continued)
Page 762 of 1803
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay........... 8Wa-42
A/C Compressor Clutch................ 8Wa-42
A/C-Heater Control................... 8Wa-42
A/C High Pressure Switch.............. 8Wa-42
A/C Low Pressure Switch............... 8Wa-42
A/C Pressure Transducer............... 8Wa-42
Accelerator Pedal Position Sensor........ 8Wa-30
Airbag Control Module................. 8Wa-43
Ambient Temperature Sensor............ 8Wa-45
Antenna Module...................... 8Wa-47
Antenna............................ 8Wa-47
Ash Receiver Lamp................... 8Wa-44
Auto Shut Down Relay................. 8Wa-30
Back-Up Lamp Switch................. 8Wa-31
Battery Temperature Sensor......... 8Wa-20, 30
Battery............................. 8Wa-20
Blend Door Actuator................... 8Wa-42
Blower Motor Relay................... 8Wa-42
Blower Motor Resistor Block............ 8Wa-42
Blower Motor........................ 8Wa-42
Body Control Module.................. 8Wa-45
Boost Pressure Sensor................. 8Wa-30
Brake Lamp Switch................... 8Wa-33
Brake Pressure Switch................. 8Wa-35
Cabin Heater Relay................... 8Wa-42
Cabin Heater........................ 8Wa-42
Camshaft Position Sensor.............. 8Wa-30
Capacitor........................... 8Wa-30
Cargo Lamp......................... 8Wa-44
CD Changer......................... 8Wa-47
Center High Mounted Stop Lamp........ 8Wa-51
Cigar Lighter........................ 8Wa-41
Circuit Breakers...................... 8Wa-12
Clockspring................. 8Wa-33, 41, 43, 47
Clutch Interlock Switch................ 8Wa-21
Clutch Switch Override Relay........... 8Wa-21
Coil On Plugs........................ 8Wa-30
Coil Rail............................ 8Wa-30
Compass Mini-Trip Computer........... 8Wa-49
Controller Antilock Brake.............. 8Wa-35
Courtesy Lamps...................... 8Wa-44
Crankshaft Position Sensor............. 8Wa-30
Curtain Airbags...................... 8Wa-43
Cylinder Lock Switches................ 8Wa-61
Data Link Connector.................. 8Wa-18
Daytime Running Lamp Relay........... 8Wa-50
Defogger Relay....................... 8Wa-48
Diagnostic Junction Port............... 8Wa-18
Dome Lamp......................... 8Wa-44
Door Ajar Switches.................... 8Wa-45
Door Lock Motor/Ajar Switches.......... 8Wa-61
Door Lock Relay...................... 8Wa-61Component Page
Door Lock Switches................... 8Wa-61
Door Speakers....................... 8Wa-47
Driver Airbag Squib 1................. 8Wa-43
Driver Airbag Squib 2................. 8Wa-43
Driver Door Unlock Relay.............. 8Wa-61
Driver Seat Belt Switch................ 8Wa-40
Driver Seat Belt Tensioner.............. 8Wa-43
EGR Solenoid........................ 8Wa-30
Electric Brake Provision................ 8Wa-54
Engine Control Module................ 8Wa-30
Engine Coolant Level Sensor............ 8Wa-40
Engine Coolant Temperature Sensor...... 8Wa-30
Engine Oil Pressure Sensor............. 8Wa-30
EVAP/Purge Solenoid.................. 8Wa-30
Flip-Up Glass Release Motor............ 8Wa-61
Flip-Up Glass Release Switch........... 8Wa-61
Fog Lamps.......................... 8Wa-50
Front Fog Lamp Relay................. 8Wa-50
Front Wiper Motor.................... 8Wa-53
Fuel Heater Relay.................... 8Wa-30
Fuel Heater......................... 8Wa-30
Fuel Injectors........................ 8Wa-30
Fuel Pressure Sensor.................. 8Wa-30
Fuel Pressure Solenoid................. 8Wa-30
Fuel Pump Module.................... 8Wa-30
Fuel Pump Relay..................... 8Wa-30
Fuses........................... 8Wa-10, 12
Fusible Link......................... 8Wa-20
Grounds............................ 8Wa-15
Generator........................... 8Wa-20
Glow Plugs.......................... 8Wa-30
Hazard Switch/Combination Flasher...... 8Wa-52
Headlamp Leveling Switch.............. 8Wa-50
Headlamps.......................... 8Wa-50
Heated Seats........................ 8Wa-63
High Beam Relay..................... 8Wa-50
Horns.............................. 8Wa-41
Hood Ajar Switch..................... 8Wa-45
Idle Air Control Motor................. 8Wa-30
Ignition Switch....................... 8Wa-10
Impact Sensors....................... 8Wa-43
Input Speed Sensor................... 8Wa-31
Instrument Cluster................... 8Wa-40
Instrument Panel Speakers............. 8Wa-47
Intake Air Temperature Sensor.......... 8Wa-30
Intrusion Sensor..................... 8Wa-49
Junction Block....................... 8Wa-12
Knock Sensor........................ 8Wa-30
Leak Detection Pump.................. 8Wa-30
Leveling Motors...................... 8Wa-50
License Lamp........................ 8Wa-51
Line Pressure Sensor.................. 8Wa-31
KJ8W-02 COMPONENT INDEX8Wa-02-1
Page 764 of 1803
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch Relay . . . 8Wa-10-11, 13, 22,
26
A/C Compressor Clutch.............. 8Wa-10-26
Auto Shut Down Relay...... 8Wa-10-10, 12, 19, 22
Battery....................... 8Wa-10-10, 12
Blower Motor Relay........... 8Wa-10-10, 12, 14
Blower Motor..................... 8Wa-10-14
Body Control Module................ 8Wa-10-23
Cabin Heater Relay........... 8Wa-10-13, 22, 26
Cabin Heater...................... 8Wa-10-26
Camshaft Position Sensor............ 8Wa-10-22
Capacitor...................... 8Wa-10-19, 21
Circuit Breaker No. 1............... 8Wa-10-16
Circuit Breaker No. 3 (JB)........... 8Wa-10-27
Clutch Interlock Switch.............. 8Wa-10-28
Clutch Switch Override Relay......... 8Wa-10-28
Coil On Plug No. 1................. 8Wa-10-21
Coil On Plug No. 2................. 8Wa-10-21
Coil On Plug No. 3................. 8Wa-10-21
Coil On Plug No. 4................. 8Wa-10-21
Coil On Plug No. 5................. 8Wa-10-21
Coil On Plug No. 6................. 8Wa-10-21
Coil Rail......................... 8Wa-10-19
Controller Antilock Brake . 8Wa-10-10, 11, 12, 13, 14
Daytime Running Lamp Relay........ 8Wa-10-16
Defogger Relay.................... 8Wa-10-24
EGR Solenoid..................... 8Wa-10-22
Engine Control Module.............. 8Wa-10-22
Fuel Heater Relay............... 8Wa-10-13, 18
Fuel Heater....................... 8Wa-10-18
Fuel Injector No. 1................. 8Wa-10-20
Fuel Injector No. 2................. 8Wa-10-20
Fuel Injector No. 3................. 8Wa-10-20
Fuel Injector No. 4................. 8Wa-10-20
Fuel Injector No. 5................. 8Wa-10-20
Fuel Injector No. 6................. 8Wa-10-20
Fuel Pressure Solenoid.............. 8Wa-10-22
Fuel Pump Module................. 8Wa-10-26
Fuel Pump Relay................ 8Wa-10-11, 26
Fuse 1.................. 8Wa-10-10, 12, 14, 25
Fuse 2.................. 8Wa-10-10, 12, 14, 15
Fuse 3.................. 8Wa-10-10, 12, 16, 25
Fuse 4..................... 8Wa-10-10, 12, 14
Fuse 5.................. 8Wa-10-10, 12, 17, 18
Fuse 6............... 8Wa-10-10, 12, 19, 22, 24
Fuse 7..................... 8Wa-10-10, 12, 15
Fuse 8..................... 8Wa-10-10, 12, 23
Fuse 9.................. 8Wa-10-10, 12, 13, 24
Fuse 10.............. 8Wa-10-10, 12, 13, 15, 18
Fuse 11.................... 8Wa-10-13, 15, 18
Fuse 12............ 8Wa-10-10, 11, 13, 15, 17, 18
Fuse 13............... 8Wa-10-10, 11, 13, 23, 27
Fuse 14.................... 8Wa-10-11, 13, 23
Fuse 15................. 8Wa-10-11, 13, 25, 27Component Page
Fuse 16................. 8Wa-10-19, 20, 22, 24
Fuse 17.......................... 8Wa-10-24
Fuse 18.......................... 8Wa-10-24
Fuse 19.................... 8Wa-10-11, 13, 24
Fuse 20.......................... 8Wa-10-27
Fuse 21.................... 8Wa-10-11, 13, 26
Fuse 22.......................... 8Wa-10-27
Fuse 24.................... 8Wa-10-11, 26, 29
Fuse 25................. 8Wa-10-11, 13, 14, 29
Fuse 26................. 8Wa-10-12, 19, 20, 22
Fuse 28.......................... 8Wa-10-28
Fuse 29.......................... 8Wa-10-15
Fuse 30.......................... 8Wa-10-24
Fuse 31.......................... 8Wa-10-27
Fuse 32.......................... 8Wa-10-27
Fuse 33.......................... 8Wa-10-16
Fuse 34.......................... 8Wa-10-15
Fuse 36.......................... 8Wa-10-27
Fuse 37.......................... 8Wa-10-29
Fuse 38.......................... 8Wa-10-29
Fuse 39.......................... 8Wa-10-29
Fusible Link................... 8Wa-10-10, 12
G202............................ 8Wa-10-23
Generator.................. 8Wa-10-10, 12, 22
Glow Plug Assembly................ 8Wa-10-18
Glow Plug Relay No. 1......... 8Wa-10-13, 18, 22
Glow Plug Relay No. 2......... 8Wa-10-13, 18, 22
High Beam Relay.................. 8Wa-10-16
Horn Relay....................... 8Wa-10-25
Ignition Switch . . . 8Wa-10-10, 11, 12, 13, 23, 27, 29
Junction Block . . . 8Wa-10-10, 11, 12, 13, 15, 16, 24,
25, 27, 29
Low Beam Relay................... 8Wa-10-25
Oxygen Sensor 1/1 Upstream......... 8Wa-10-19
Oxygen Sensor 1/2 Downstream.... 8Wa-10-19, 20
Oxygen Sensor 2/1 Upstream......... 8Wa-10-19
Oxygen Sensor 2/2 Downstream....... 8Wa-10-20
Oxygen Sensor Downstream Relay . . 8Wa-10-19, 20
Park Lamp Relay.................. 8Wa-10-16
Power Distribution Center . 8Wa-10-2, 3, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25, 26, 27, 28
Power Window Master Switch......... 8Wa-10-29
Powertrain Control Module . . 8Wa-10-11, 19, 26, 28
Radiator Fan Relay.............. 8Wa-10-10, 14
Starter Motor Relay.............. 8Wa-10-23, 28
Starter Motor..................... 8Wa-10-23
Trailer Tow Circuit Breaker..... 8Wa-10-10, 12, 15
Trailer Tow Circuit Breaker.......... 8Wa-10-15
Trailer Tow Connector............... 8Wa-10-15
Trailer Tow Relay.................. 8Wa-10-15
Transmission Control Module . . . 8Wa-10-10, 17, 28
Transmission Control Relay........ 8Wa-10-10, 17
Transmission Solenoid/TRS Assembly . . . 8Wa-10-17
KJ8W-10 POWER DISTRIBUTION8Wa-10-1
Page 862 of 1803
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8Wa-30-34
A/C Compressor Clutch Relay..... 8Wa-30-34, 2, 3
A/C High Pressure Switch............ 8Wa-30-29
A/C Low Pressure Switch.......... 8Wa-30-8, 29
A/C Pressure Transducer....... 8Wa-30-11, 23, 12
Accelerator Pedal Position Sensor...... 8Wa-30-27
Auto Shut Down Relay . . 8Wa-30-13, 14, 15, 24, 28,
31, 16, 17, 2
Battery Temperature Sensor........ 8Wa-30-30, 7
Blower Motor Relay................. 8Wa-30-31
Body Control Module.............. 8Wa-30-8, 33
Boost Pressure Sensor............ 8Wa-30-26, 28
Brake Lamp Switch............ 8Wa-30-8, 32, 33
Cabin Heater...................... 8Wa-30-34
Cabin Heater Relay................. 8Wa-30-34
Camshaft Position Sensor....... 8Wa-30-10, 9, 28
Capacitor...................... 8Wa-30-19, 17
Clockspring..................... 8Wa-30-33, 7
Clutch Switch Override Relay.... 8Wa-30-13, 8, 32
Coil On Plug No. 1................. 8Wa-30-19
Coil On Plug No. 2................. 8Wa-30-20
Coil On Plug No. 3................. 8Wa-30-19
Coil On Plug No. 4................. 8Wa-30-20
Coil On Plug No. 5................. 8Wa-30-19
Coil On Plug No. 6................. 8Wa-30-20
Coil Rail......................... 8Wa-30-17
Controller Antilock Brake............ 8Wa-30-33
Crankshaft Position Sensor...... 8Wa-30-10, 9, 27
Data Link Connector.............. 8Wa-30-25, 6
Diagnostic Junction Port........... 8Wa-30-25, 6
EGR Solenoid..................... 8Wa-30-30
Engine Control Module . . 8Wa-30-24, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34, 35, 36
Engine Coolant Temperature Sensor . 8Wa-30-11, 28,
12
Engine Oil Pressure Sensor..... 8Wa-30-11, 28, 12
Evap/Purge Solenoid................. 8Wa-30-2
Fuel Heater....................... 8Wa-30-31
Fuel Heater Relay.................. 8Wa-30-31
Fuel Injector No. 1............... 8Wa-30-18, 36
Fuel Injector No. 2............... 8Wa-30-18, 36
Fuel Injector No. 3............... 8Wa-30-18, 36
Fuel Injector No. 4............... 8Wa-30-18, 36
Fuel Injector No. 5................. 8Wa-30-18
Fuel Injector No. 6................. 8Wa-30-18
Fuel Pressure Sensor............... 8Wa-30-36
Fuel Pressure Solenoid.............. 8Wa-30-31
Fuel Pump Module............. 8Wa-30-30, 4, 5
Fuel Pump Relay.............. 8Wa-30-4, 2, 3, 5
Fuse 2........................... 8Wa-30-23
Fuse 6................... 8Wa-30-24, 28, 31, 2Component Page
Fuse 10.......................... 8Wa-30-35
Fuse 11.......................... 8Wa-30-35
Fuse 12....................... 8Wa-30-31, 33
Fuse 15...................... 8Wa-30-25, 2, 3
Fuse 16...... 8Wa-30-13, 14, 15, 24, 30, 34, 35, 16
Fuse 21.......................... 8Wa-30-34
Fuse 24...................... 8Wa-30-31, 2, 3
Fuse 26.................. 8Wa-30-18, 24, 17, 2
Fuse 28.......................... 8Wa-30-13
G100.................... 8Wa-30-19, 27, 17, 3
G101............................ 8Wa-30-23
G103................. 8Wa-30-15, 23, 31, 34, 16
G104............................ 8Wa-30-27
G111 ............................ 8Wa-30-31
G112 .......................... 8Wa-30-8, 23
G320........................... 8Wa-30-4, 5
Generator.................. 8Wa-30-24, 4, 3, 5
Glow Plug Assembly................ 8Wa-30-35
Glow Plug Relay No. 1.............. 8Wa-30-35
Glow Plug Relay No. 2.............. 8Wa-30-35
Idle Air Control Motor............ 8Wa-30-21, 22
Ignition Switch.................... 8Wa-30-32
Intake Air Temperature Sensor..... 8Wa-30-11, 12
Junction Block........... 8Wa-30-25, 31, 33, 2, 3
Knock Sensor...................... 8Wa-30-8
Leak Detection Pump.............. 8Wa-30-4, 5
Left Speed Control Switch.......... 8Wa-30-33, 7
Manifold Absolute Pressure Sensor . . 8Wa-30-11, 12
Oxygen Sensor 1/1 Upstream...... 8Wa-30-14, 15
Oxygen Sensor 1/2 Downstream . 8Wa-30-13, 14, 15
Oxygen Sensor 2/1 Upstream......... 8Wa-30-16
Oxygen Sensor 2/2 Downstream.... 8Wa-30-13, 16
Oxygen Sensor Downstream Relay . . 8Wa-30-13, 15,
16
Power Distribution Center . . 8Wa-30-13, 14, 15, 23,
24, 28, 30, 31, 34, 35, 16, 17, 2, 3
Power Steering Pressure Switch....... 8Wa-30-23
Powertrain Control Module . . . 8Wa-30-10, 13, 20, 8,
11, 14, 15, 18, 19, 21, 9, 23, 4, 12, 16, 17, 2, 22, 3,
6, 7, 5
Radiator Fan Motor................. 8Wa-30-23
Radiator Fan Relay................. 8Wa-30-23
Right Speed Control Switch......... 8Wa-30-33, 7
Shifter Assembly................. 8Wa-30-8, 32
Speed Control Servo................. 8Wa-30-8
Starter Motor Relay................ 8Wa-30-13
Throttle Position Sensor.......... 8Wa-30-21, 22
Transfer Case Position Sensor.... 8Wa-30-9, 23, 32
Transmission Control Module . . 8Wa-30-10, 8, 22, 6
Transmission Solenoid/Trs Assembly.... 8Wa-30-10
Water In Fuel Sensor............... 8Wa-30-29
KJ8W-30 FUEL/IGNITION SYSTEM8Wa-30-1
Page 1057 of 1803
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
Page 1110 of 1803
EGR SOLENOID (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
1 A71 18DG/RD FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K35 18GY/YL EGR SOLENOID CONTROL
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
1 Z108 14BK/DG GROUND
2 Z108 14BK/DG GROUND
3 K20 18DG GENERATOR FIELD CONTROL
4 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
5 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
6- -
7 D25 20VT/YL PCI BUS
8 K944 20BK/LB CAMSHAFT POSITION SENSOR GROUND
9 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 - -
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K81 20VT/TN ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20BK/VT FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 F92 20YL/BR BATTERY SENSE (+)
20 Z109 20BK/DB BATTERY SENSE (-)
21 K4 20BK/LB SENSOR GROUND
22 F1 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 K6 20VT/WT SENSOR REFERENCE VOLTAGE B
24 K3 20LB/BK CRANKSHAFT POSITION SENSOR SIGNAL 2
25 - -
26 - -
27 - -
28 - -
29 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT
30 G60 20GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
31 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
32 K118 20PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND
35 K852 20VT/WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
36 - -
37 - -
38 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
39 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Y101 20BK/OR CRANKSHAFT POSITION SENSOR SHIELD
43 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL 1
KJ8W-80 CONNECTOR PIN-OUTS8Wa-80-55
Page 1111 of 1803
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
44 - -
45 - -
46 - -
47 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
48 K29 20WT/PK BRAKE SWITCH SENSE
49 - -
50 - -
51 - -
52 - -
53 - -
54 - -
55 B22 20DG/YL VEHICLE SPEED SIGNAL
56 - -
57 - -
58 - -
59 - -
60 K7 20OR FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
62 - -
63 - -
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 - -
67 - -
68 - -
69 C13 20DG A/C COMPRESSOR CLUTCH RELAY CONTROL
70 - -
71 - -
72 K236 20GY/PK GLOW PLUG RELAY RELAY NO. 2 CONTROL
73 - -
74 K90 20TN CLUTCH SWITCH OVERRIDE RELAY CONTROL
75 K132 20DG/LB CABIN HEATER RELAY CONTROL
76 - -
77 K152 20WT GLOW PLUG RELAY NO. 1 CONTROL
78 - -
79 - -
80 K46 20OR/BK FUEL PRESSURE SOLENOID CONTROL
81 K46 20OR/BK FUEL PRESSURE SOLENOID CONTROL
ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY
CAV CIRCUIT FUNCTION
82 D21 20PK SCI TRANSMIT
83 - -
84 - -
85 - -
86 - -
87 - -
88 - -
89 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
8Wa - 80 - 56 8W-80 CONNECTOR PIN-OUTSKJ
Page 1159 of 1803
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Coil On Plug No.5 (3.7L) BK Left Side of Engine Near
Fuel Injector No.51
Coil On Plug No.6 (3.7L) BK Right Side of Engine Near
Fuel Injector No.62
Coil Rail (2.4L) BK Right Side of Engine 11, 12
Combination Flasher WT Under Left Side of
Instrument PanelN/S
Compass Mini-Trip Computer BK At Overhead Console N/S
Controller Antilock Brake BK Left Side of Engine
Compartment30
Crankshaft Position Sensor (2.4L) BK Top of Engine N/S
Crankshaft Position Sensor (3.7L) BK Right Lower Side of Engine 4
Crankshaft Position Sensor (Diesel) BK Right Rear Side of Engine 17
Data Link Connector BK Under Center of Instrument
PanelN/S
Diagnostic Junction Port BK Under Center of Instrument
Panel49
Dome Lamp (Base) BK On Headliner N/S
Driver Airbag Squib 1 GY In Steering Wheel N/S
Driver Airbag Squib 2 BK In Steering Wheel N/S
Driver Seat Belt Switch LG At Drive Seat N/S
Driver Seat Belt Tensioner (LHD) YL Lower Left B-Pillar 35
Driver Seat Belt Tensioner (RHD) YL Lower Right B-Pillar 39
EGR Solenoid Right Rear Side of Engine
Compartment27
Engine Control Module C1 BK Left Rear Side of Engine
Compartment19
Engine Control Module C2 BK Left Rear Side of Engine
Compartment19
Engine Coolant Level Sensor (Diesel) LG Rear Side of Engine
Compartment18
Engine Coolant Temperature Sensor
(Diesel)BK Left Side of Engine 20
Engine Coolant Temperature Sensor
(Gas)BK Front Side of Engine 2
Engine Oil Pressure Sensor (2.4L) BK Top of Engine N/S
Engine Oil Pressure Sensor (3.7L) BK Left Front Side of Engine 3
Engine Oil Pressure Sensor (Diesel) BK Right Rear Side of Engine 17
Engine Starter Motor Right Front Side of Engine 20
Evap/Purge Solenoid BK At Solenoid N/S
Flip-Up Glass Release Motor BK In Tailgate 46
Flip-Up Glass Release Switch WT In Tailgate 46
Front Washer Pump BK Right Front Side of Engine
Compartment28
Front Wiper Motor (LHD) BK Left Side of Cowl 24
8Wa - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONKJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1238 of 1803
(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the eight M11 bolts.
(5) Coat the four M8 cylinder head bolts with
MopartLock and Seal Adhesivethen install the
bolts.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tighten the bolts in sequence using the follow-
ing steps and torque values:
²Step 1: Tighten bolts 1±10, 27 N´m (20 ft. lbs.).
²Step 2: Verify that bolts 1±10, all reached 27
N´m (20 ft. lbs.), by repeating step-1 without loosen-
ing the bolts. Tighten bolts 11 thru 14 to 14 N´m (10
ft. lbs.).
²Step 3: Tighten bolts 1±10, 90 degrees (Fig. 11).
²Step 4: Tighten bolts 1±10, 90 degrees, again.
Tighten bolts 11±14, 26 N´m (19 ft. lbs.)
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V6 mark on the gear then using
Special Tool 8428 Camshaft Wrench, position the
gear onto the camshaft.
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.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the left side secondary chain guide.(10) Install the cylinder head access plug.
(11) Re-set and Install the left side secondary
chain tensioner.
(12) Remove Special Tool 8429.
(13) Install the timing chain cover.
(14) Install the crankshaft damper. Tighten
damper bolt 175 N´m (130 Ft. Lbs.).
(15) Install the power steering pump.
(16) Install the fan blade assembly and fan
shroud.
(17) Install the cylinder head cover.
(18) Install the intake manifold.
(19) Refill the cooling system
(20) Raise the vehicle.
(21) Install the exhaust pipe onto the left exhaust
manifold.
(22) Lower the vehicle.
(23) Connect the negative cable to the battery.
(24) Start the engine and check for leaks.
CAMSHAFT(S)
DESCRIPTION
The camshafts consist of powdered metal steel
lobes which are sinter-bonded to a steel tube. Four
bearing journals are machined into the camshaft.
Camshaft end play is controlled by two thrust walls
that border the nose piece journal. Engine oil enters
the hollow camshafts at the third journal and lubri-
cates every intake lobe rocker through a drilled pas-
sage in the intake lobe.
Fig. 10 Proper Tool Usage For Surface Preparation
1 - PLASTIC/WOOD SCRAPERFig. 11 CYLINDER HEAD TIGHTENING SEQUENCE
KJENGINE - 3.7L 9 - 23
CYLINDER HEAD - LEFT (Continued)
Page 1242 of 1803
valve. Remove the valve and examine the valve face.
If the blue is transferred below the top edge of the
valve face, lower the valve seat using a 15 degree
stone. If the blue is transferred to the bottom edge of
the valve face, raise the valve seat using a 65 degree
stone.
(3) When the seat is properly positioned the width
of the intake seat must be 1.75 ± 2.36 mm (0.0689 ±
0.0928 in.) and the exhaust seat must be 1.71 ± 2.32
mm (0.0673 ± 0.0911 in.).
(4) Check the valve spring installed height after
refacing the valve and seat. The installed height for
both intake and exhaust valve springs must not
exceed 41.44 mm (1.6315 in.).
(5) The valve seat and valve face must maintain a
face angle of 44.5 ± 45 degrees angle (Fig. 17).
REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and lash adjusters. Refer
to procedures in this section (Fig. 18).
(2) Remove the camshaft bearing caps and the
camshaft.NOTE: All six valve springs and valves are removed
in the same manner; this procedure only covers
one valve and valve spring.
(3) Using Special Tool C-3422±B or C-3422±C
Valve Spring Compressor and Special tool 8519
Adapter, compress the valve spring.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the valve spring compressor.
(6) Remove the spring retainer, and the spring.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the valve from the cylinder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the valve stem seal. Mark the valve for
proper installation.
Fig. 17 Valve Assembly Configuration
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 18 Rocker Arm Removal
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
KJENGINE - 3.7L 9 - 27
INTAKE/EXHAUST VALVES & SEATS (Continued)