Front light JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Raise vehicle on hoist.
(3) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELT TENSION-
ERS - REMOVAL)
(4) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(5) Remove air conditioner/generator belt tensioner
and pulley assembly. (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL)
(6) Remove timing belt lower front cover bolts and
remove cover. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - REMOVAL)
(7) Lower vehicle.
(8) Remove bolts attaching timing belt upper front
cover and remove cover. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL)
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(9) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 95).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(10) Install 6 mm Allen wrench into belt tensioner.
Before rotating the tensioner, insert the long end of a
1/8º or 3 mm Allen wrench into the pin hole on the
front of the tensioner (Fig. 96). While rotating the
tensioner counterclockwise, push in lightly on the
1/8º or 3 mm Allen wrench, until it slides into the
locking hole.
(11) Remove timing belt.
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 97).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
Fig. 95 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
KJENGINE9s-55

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA SUPPORT
REMOVAL.............................3
INSTALLATION..........................3
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 3
SPECIFICATIONS - TORQUE.............6
FRONT SKID PLATE
REMOVAL.............................6
INSTALLATION..........................6
ENGINE CRADLE CROSSMEMBER
REMOVAL.............................6
INSTALLATION..........................6TRANSFER CASE SKID PLATE
REMOVAL.............................7
INSTALLATION..........................7
REAR CROSSMEMBER
REMOVAL.............................7
INSTALLATION..........................7
FRONT TOW HOOK
REMOVAL.............................8
INSTALLATION..........................8
REAR TOW HOOK
REMOVAL.............................8
INSTALLATION..........................8
TRAILER HITCH
REMOVAL.............................9
INSTALLATION..........................9
FUEL TANK SKID PLATE
REMOVAL.............................9
INSTALLATION..........................9
FRONT FASCIA
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Raise and support vehicle.
(3) Remove the front wheel opening flare moldings.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL
OPENING FLARE MOLDINGS - REMOVAL)
(4) Remove the four screws through the lower air
dam (Fig. 1).
(5) Disconnect the electrical connectors:
²Fascia to grille opening reinforcement. (Fig. 1)
²Side repeater lights, both sides, if equipped.
(Fig. 2)
(6) Remove the six push pins from the grill sup-
port.
(7) Remove the rivets attaching the air dam to the
wheelhouse splash shield.
(8) Release the support tabs beneath the head-
lamps.
(9) Release the inner support clips from within the
fascia between the lights (Fig. 2).
(10) Remove the fascia.
Fig. 1 FRONT FASCIA
1 - ELECTRICAL CONNECTOR
2 - PUSH PINS
3 - FRONT FASCIA ASSEMBLY
4 - LOWER SCREWS
5 - PLASTIC RIVETS (2)
6 - INNER SUPPORT CLIPS
7 - SUPPORT TABS
KJFRAMES & BUMPERS 13 - 1

INSTALLATION
(1) Install the fascia.
(2) Connect the electrical connectors.
²Side repeater lights, both sides, if equipped.
²Fascia to grille opening reinforcement.
(3) Install the six push pin fasteners into the grill
support.
(4) Install the four screws through the lower air
damn.
(5) Install new rivets attaching the air dam to the
wheelhouse splash shield.
(6) Install the front wheel opening flare moldings.
(Refer to 23 - BODY/EXTERIOR/WHEEL OPENING
FLARE MOLDING - INSTALLATION)
(7) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
REAR FASCIA
REMOVAL
(1) Remove the wheel flares (rear). (Refer to 23 -
BODY/EXTERIOR/REAR WHEEL OPENING
FLARE MOLDINGS - REMOVAL)
(2) Remove the rear lamp units. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
REAR LAMP UNIT - REMOVAL)(3) Remove the four side bolts. (Fig. 3)
(4) Remove the four bottom rivets.
(5) Remove the 3 bolts along the upper edge.
(6) Separate the side plastic retainers and remove
the fascia from the vehicle.
INSTALLATION
NOTE: Fascia must be pushed completely forward
to allow the plastic retainers full engagement in
their respective slots.
(1) Install the fascia and insert the plastic retain-
ers.
(2) Install the three upper bolts.
(3) Install the four side bolts.
(4) Install four bottom rivets.
(5) Install the rear lamp units. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/REAR
LAMP UNIT - INSTALLATION)
(6) Install the rear half wheel opening flares.
(Refer to 23 - BODY/EXTERIOR/WHEEL OPENING
FLARE MOLDING - INSTALLATION)
Fig. 2 FASCIA INNER SUPPORT
1 - INNER SUPPORT CLIP
2 - SIDE REPEATER CONNECTOR (IF EQUIPPED)
3 - FASCIA ASSEMBLY
4 - FOG LAMP
Fig. 3 REAR FASCIA
1 - REAR FASCIA ASSEMBLY
2 - PLASTIC RETAINERS
3 - FASCIA SUPPORT BRACKET
4 - SIDE BOLTS
5 - RIVETS
6 - UPPER BOLTS
13 - 2 FRAMES & BUMPERSKJ
FRONT FASCIA (Continued)

INSTALLATION
2.4L
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.(3) Install sensor into engine block with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
3.7L
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
Fig. 6 CKP SENSOR LOCATION-2.4L
1 - RIGHT FRONT ENGINE MOUNT
2 - CKP SENSOR
3 - MOUNTING BOLT
4 - ELECTRICAL CONNECTOR
Fig. 7 CKP AND O-RING-2.4L
1 - CKP SENSOR
2 - O-RING
Fig. 8 CKP - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
14 - 32 FUEL INJECTIONKJ
CRANKSHAFT POSITION SENSOR (Continued)

NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Raise the front wheels off the ground.
(3) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(4) Check the fluid level add if necessary.
(5) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(6) Stop the engine and check the fluid level and
refill as required.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(7) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
(8) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
REMOVAL
REMOVAL - 3.7L
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the radiator cross member (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).
(3) Remove the engine cooling fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(4) Remove the fan shroud
(5) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove the power steering high pressure hose
at the pump.
(7) Remove the return hose at the pump.
(8) Remove the three bolts securing the pump to
the bracket thru the holes in the pulley. (Fig. 3)
(9) Remove the pump from the vehicle.
REMOVAL - 2.4L
CAUTION: On vehicles equipped with the 2.4L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the serpentine drive belt.
(3) Remove the power steering high pressure hose
at the pump using care not to remove the flow con-
trol valve.
(4) Remove the return hose at the pump.
Fig. 2 FLUID RESERVOIR - 2.4L
Fig. 3 POWER STEERING PUMP - 3.7L
1 - MOUNTING BOLTS
2 - RESERVOIR
3 - STEEL PULLEY
19 - 18 PUMPKJ
PUMP (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
23 - 2 BODYKJ
BODY (Continued)

(2) Install the three screws.
(3) Install the fuel cap.
GRILLE
REMOVAL
(1) Remove the upper screws. (Fig. 4)
(2) Roll the grille forward and disengage the two
grille hooks under the headlamp units.
(3) Lift the grille forward and up off of the location
tabs at the bottom and remove.
INSTALLATION
(1) Install the grille onto the locating tabs at the
bottom.
(2) Push the grille back and snap into the hooks in
the grille opening reinforcement.
(3) Check that the black welts at the outboard
ends of the grille have a uniform appearance relative
to the fender and install the screws.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Remove the front fascia. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCIA -
REMOVAL)
(3) Disconnect the electrical connectors. (Fig. 5)
(4) Disconnect the rubber side flap push pin con-
nectors.
(5) Remove the seven bolts and remove the grille
opening reinforcement.
(6) Disconnect the headlamp units electrical con-
nectors.
(7) Remove the headlamp units. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL)
INSTALLATION
(1) Install the headlamp units. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(2) Connect the headlamp unit electrical connec-
tors.
(3) Install the grille opening reinforcement and
install the seven bolts.
(4) Connect the rubber side flap and install the
push pin connectors.
(5) Connect the electrical connectors. (Fig. 5)
(6) Install the front fascia. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION)
(7) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
Fig. 3 FUEL FILL DOOR/HOUSING
1 - FUEL FILL DOOR
2 - HOUSING TABS
Fig. 4 GRILLE
1 - GRILLE OPENING REINFORCEMENT
2 - SCREWS (4)
3 - GRILLE CLIPS
23 - 142 EXTERIORKJ
FUEL FILL DOOR/HOUSING (Continued)

(1) Open the glove box.
(2) Remove the two striker screws and remove the
latch striker.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install the striker and install the two screws.
(2) Loosen the screws to adjust if necessary.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL)
(3) Remove the speakers.
(4) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)
(5) Remove the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL)
(6) Remove the four nuts and remove the center
support bracket. (Fig. 6)
(7) Remove the steering column. (Refer to 19 -
STEERING/COLUMN - REMOVAL)
(8) Remove the drivers side cowl trim cover. (Refer
to 23 - BODY/INTERIOR/COWL TRIM COVER -
REMOVAL)
(9) Disconnect the wire harness connector behind
the drivers side cowl trim cover.
(10) Disconnect the green and light blue wire har-
ness bulk connectors at the junction block. (Fig. 1)
(11) Disconnect the electrical connector at the
inner side of the pedal support bracket. (Fig. 2)
(12) Remove the two bolts at the front of the pedal
support bracket. (Fig. 2)
(13) Remove the two bolts from the bottom side of
the pedal support bracket. (Fig. 2)
Fig. 1 JUNCTION BLOCK CONNECTORS
1 - ELECTRICAL CONNECTOR
2 - ELECTRICAL CONNECTOR
3 - PEDAL SUPPORT BRACKET
4 - JUNCTION BLOCK
KJINSTRUMENT PANEL 23 - 149
GLOVE BOX LATCH STRIKER (Continued)

The pump contains a 3 port solenoid, a pump that
contains a switch, a spring loaded canister vent valve
seal, 2 check valves and a spring/diaphragm.
OPERATION
Immediately after a cold start, engine temperature
between 40ÉF and 86ÉF, the 3 port solenoid is briefly
energized. This initializes the pump by drawing air
into the pump cavity and also closes the vent seal.
During non-test test conditions, the vent seal is held
open by the pump diaphragm assembly which pushes
it open at the full travel position. The vent seal will
remain closed while the pump is cycling. This is due
to the operation of the 3 port solenoid which prevents
the diaphragm assembly from reaching full travel.
After the brief initialization period, the solenoid is
de-energized, allowing atmospheric pressure to enter
the pump cavity. This permits the spring to drive the
diaphragm which forces air out of the pump cavity
and into the vent system. When the solenoid is ener-
gized and de-energized, the cycle is repeated creating
flow in typical diaphragm pump fashion. The pump
is controlled in 2 modes:
PUMP MODE:The pump is cycled at a fixed rate
to achieve a rapid pressure build in order to shorten
the overall test time.
TEST MODE:The solenoid is energized with a
fixed duration pulse. Subsequent fixed pulses occur
when the diaphragm reaches the switch closure
point.
The spring in the pump is set so that the system
will achieve an equalized pressure of about 7.5 inches
of water.
When the pump starts, the cycle rate is quite high.
As the system becomes pressurized pump rate drops.
If there is no leak the pump will quit. If there is a
leak, the test is terminated at the end of the test
mode.
If there is no leak, the purge monitor is run. If the
cycle rate increases due to the flow through the
purge system, the test is passed and the diagnostic is
complete.
The canister vent valve will unseal the system
after completion of the test sequence as the pump
diaphragm assembly moves to the full travel position.
REMOVAL
The Leak Detection Pump (LDP) is attached (bolt-
ed) to the front of the fuel tank (Fig. 3). The LDP
fresh air filter is located on the end of a hose. This
hose is attached to the fuel fill tube assembly below
and near the fuel fill opening (Fig. 1). The LDP and
LDP filter are typically replaced (serviced) as one
unit.
(1) Raise vehicle.(2) Carefully remove two 3/4º vent hoses at sides
of LDP.
(3) Carefully remove other vapor/vacuum hoses
from LDP.
(4) Place a hydraulic jack under fuel tank.
(5) Loosen 2 fuel tank strap mounting bolts at
front of tank about 10 turns.
(6) Lower front of fuel tank about 1/2º.
(7) Remove 2 LDP mounting nuts (Fig. 3) and
lower LDP slightly to gain access to electrical connec-
tor (Fig. 4).
(8) Disconnect electrical connector at LDP. To dis-
connect: Slide red colored tab upward. Push on black
colored tab while removing connector.
(9) Remove LDP from vehicle.
INSTALLATION
The Leak Detection Pump (LDP) is attached (bolt-
ed) to the front of the fuel tank. The LDP filter is
located on the end of a hose. This hose is attached to
the fuel fill tube assembly below and near the fuel
fill opening. The LDP and LDP filter are replaced
(serviced) as one unit.
(1) Install electrical connector to LDP. Push red
colored tab downward to lock connector to LDP.
(2) Position LDP and LDP bracket to fuel tank
mounting studs and install 2 nuts. Tighten nuts to 1
N´m (11 in. lbs.) torque.
(3) Raise fuel tank to body and tighten 2 strap
bolts to 61 N´m (45 ft. lbs.) torque.
Fig. 3 LDP LOCATION / MOUNTING
1 - LDP
2 - FLOW MANAGEMENT VALVE
3 - MOUNTING NUTS
4 - FRONT OF FUEL TANK
25 - 28 EVAPORATIVE EMISSIONSKJ
LEAK DETECTION PUMP (Continued)

(13) If vacuum is not present, disconnect each PCV
system hose at top of each crankcase breather (Fig.
8). Check for obstructions or restrictions.
(14) If vacuum is still not present, remove each
PCV system crankcase breather (Fig. 8) from each
cylinder head. Check for obstructions or restrictions.
If plugged, replace breather. Tighten breather to 12
N´m (106 in. lbs.) torque. Do not attempt to clean
breather
(15) If vacuum is still not present, disconnect each
PCV system hose at each fitting and check for
obstructions or restrictions.
REMOVAL
2.4L
The PCV valve is attached to the left/front side of
the valve cover (Fig. 5). It is secured with 1 bolt. An
o-ring is used to seal valve to valve cover (Fig. 6).
(1) Remove hose from valve (Fig. 5). Check condi-
tion of hose.
(2) Remove 1 bolt.
(3) Remove PCV valve from valve cover.
(4) Check condition of valve o-ring.
3.7L
The PCV valve is located on the oil filler tube (Fig.
12). Two locating tabs are located on the side of the
valve (Fig. 12). These 2 tabs fit into a cam lock in the
oil filler tube. An o-ring seals the valve to the filler
tube.
(1) Disconnect PCV line/hose (Fig. 12) by discon-
necting rubber hose at PCV valve fitting.
(2) Remove PCV valve at oil filler tube by rotating
PCV valve downward (counter-clockwise) until locat-
ing tabs have been freed at cam lock (Fig. 12). After
tabs have cleared, pull valve straight out from filler
tube.To prevent damage to PCV valve locating
tabs, valve must be pointed downward for
removal. Do not force valve from oil filler tube.
(3) After valve is removed, check condition of valve
o-ring (Fig. 12).
INSTALLATION
2.4L
(1) Check condition of PCV valve o-ring.
(2) Install PCV valve into valve cover.
(3) Install PCV valve mounting bolt.
(4) Install hose to valve.3.7L
The PCV valve is located on the oil filler tube. Two
locating tabs are located on the side of the valve.
These 2 tabs fit into a cam lock in the oil filler tube.
An o-ring seals the valve to the filler tube.
(1) Return PCV valve back to oil filler tube by
placing valve locating tabs into cam lock. Press PCV
valve in and rotate valve upward. A slight click will
be felt when tabs have engaged cam lock. Valve
should be pointed towards rear of vehicle.
(2) Connect PCV line/hose and rubber hose to PCV
valve.
Fig. 12 PCV Valve/Oil Filler Tube Location
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - P C V VA LV E
25 - 32 EVAPORATIVE EMISSIONSKJ
PCV VALVE (Continued)