Gasket install JEEP LIBERTY 2002 KJ / 1.G User Guide

(9) Remove the accessory drive bracket.
(10) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- REMOVAL).
(11) Remove timing belt idler pulley.
(12) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(13) Remove the timing belt rear cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(14) Remove water pump to engine attaching
screws (Fig. 15).
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION - 2.4L ENGINE
(1) Install new O-ring gasket in water pump body
O-ring locating groove (Fig. 16).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may be damaged and
cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 103.4 Kpa (15 psi) with pressure tester and
check water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(5) Install camshaft sprockets and target ring.
Torque bolts to 101 N´m (75 ft. lbs.) while holding
camshaft sprocket with Special tool C-4687 and
adaptor C-4687-1.
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(7) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- INSTALLATION).
Fig. 15 Water Pump - 2.4L
1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 16 Water Pump Body
1 - IMPELLER
2 - WATER PUMP BODY
3 - O-RING LOCATING GROOVE
7s - 28 ENGINEKJ
WATER PUMP - 2.4L (Continued)

headliner hose is glued to top of the headliner and
routed along the right roof side rail to the rear of the
vehicle. At the rear of the vehicle, the headliner hose
passes through a hole at the rear portion of the roof
rear inner header panel and is connected to the rear
check valve. From the rear check valve, there is a
short section of hose that connects the rear check
valve to the rear washer nozzle.
Washer hose is available for service only as roll
stock, which must then be cut to length. The head-
liner washer hose is integral to the headliner unit
and, if faulty or damaged, the headliner unit must be
replaced. However, the headliner hose is marked
with a white cut line on the A-pillar where the hose
should be cut and spliced with a plastic in-line con-
nector fitting to facilitate headliner removal without
the need to remove the instrument panel. (Refer to
23 - BODY/INTERIOR/HEADLINER - REMOVAL
AND INSTALLATION). The molded plastic washer
hose fittings cannot be repaired. If these fittings are
faulty or damaged, they must be replaced.
OPERATION
Washer fluid in the washer reservoir is pressurized
and fed by the washer pump/motor through the rear
washer system plumbing and fittings to the rear
washer nozzle located on the roof panel above the
rear flip-up glass opening. Whenever routing the
washer hose or a wire harness containing a washer
hose, it must be routed away from hot, sharp, or
moving parts; and, sharp bends that might pinch the
hose must be avoided.
REAR WASHER NOZZLE
DESCRIPTION
The rear washer nozzle is a fluidic-type unit con-
structed of molded plastic (Fig. 6). The nozzle is
secured by a snap fit in a dedicated mounting hole
located in the rear edge of the roof panel above the
rear flip-up glass opening and to the right of the
Center High Mounted Stop Lamp (CHMSL) unit. A
rubber gasket on the back of the nozzle seals the noz-
zle to the roof panel opening. The back of the nozzle
includes an integral alignment feature on the left
side, an integral engagement tab on the top, an inte-
gral latch feature on the bottom, and the washer
plumbing nipple which are all concealed between the
outer roof panel and the rear roof inner header. The
rear washer nozzle latch feature is a one time com-
ponent, and will be damaged if the nozzle is removed
from its mounting hole for service. The rear washer
nozzle cannot be adjusted or repaired. If faulty or
damaged, the entire nozzle unit must be replaced.
OPERATION
The rear washer nozzle is designed to dispense
washer fluid into the wiper pattern area on the out-
side of the rear flip-up glass. Pressurized washer
fluid is fed to the nozzle from the washer reservoir by
the washer pump/motor through a single hose, which
is attached to a barbed nipple on the back of the rear
washer nozzle. The rear washer nozzle incorporates a
fluidic design, which causes the nozzle to emit the
pressurized washer fluid as an oscillating stream to
more effectively cover a larger area of the glass area
to be cleaned.
REMOVAL
NOTE: The rear washer nozzle latch feature is a one
time component, and will be damaged if the nozzle is
removed from its mounting hole for service. If
removed from its mounting hole for any reason, the
rear washer nozzle must be replaced with a new unit.
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the bottom of the rear
washer nozzle away from the roof panel until the
latch feature at the bottom of the nozzle that secures
it in the mounting hole of the roof panel snaps.
(2) Pull the rear washer nozzle out from the roof
panel far enough to access the washer hose (Fig. 7).
(3) Disconnect the washer hose from the barbed
nipple on the back of the rear washer nozzle.
(4) Discard the rear washer nozzle.
Fig. 6 Rear Washer Nozzle
1 - ENGAGEMENT TAB (TOP)
2 - GASKET
3 - REAR WASHER NOZZLE
4 - ALIGNMENT FEATURE
5 - ORIFICE
6 - LATCH FEATURE (BOTTOM)
7 - NIPPLE
8R - 36 REAR WIPERS/WASHERSKJ
REAR WASHER HOSES/TUBES (Continued)

INSTALLATION
NOTE: The rear washer nozzle latch feature is a one
time component, and will be damaged if the nozzle
is removed from its mounting hole for service. If
removed from its mounting hole for any reason, the
rear washer nozzle must be replaced with a new
unit.
(1) Position the new rear washer nozzle to the roof
panel (Fig. 7). Be certain that a new rubber gasket is
in position on the back of the nozzle.
(2) Reconnect the washer hose to the barbed nip-
ple on the back of the rear washer nozzle.
(3) Insert the rear washer nozzle supply hose and
nipple into the mounting hole in the roof panel and
align the nozzle with the hole.
(4) Engage the tab at the top of the nozzle behind
the sheet metal at the top of the roof panel mounting
hole.
(5) Using hand pressure, press firmly and evenly
on the hood of the rear washer nozzle until the lower
latch feature snaps into place behind the sheet metal
at the bottom of the roof panel mounting hole.
REAR WIPER ARM
DESCRIPTION
The rear wiper arm is the rigid member located
between the rear wiper motor output shaft that pro-
trudes from the outer tailgate panel near the base of
the rear flip-up glass opening and the rear wiper
blade (Fig. 8). This wiper arm features an over-center
hinge that allows easy access to the tailgate and rear
flip-up glass for cleaning, after the spare tire is
removed. The wiper arm has a die cast metal pivot
end with a large tapered mounting hole at one end. A
molded plastic pivot cover is secured loosely to and
pivots on the wiper arm hinge pin to conceal the
wiper arm retaining nut. The wide end of a tapered,
stamped steel channel is secured with a hinge pin to
the pivot end of the wiper arm. One end of a long,
rigid, stamped steel strap, with a small hole near its
pivot end, is riveted and crimped within the narrow
end of the stamped steel channel. The tip of the
wiper blade end of this strap is bent back under itself
to form a small hook. Concealed within the stamped
steel channel, one end of a long spring is engaged
with a wire hook on the underside of the die cast
pivot end, while the other end of the spring is hooked
through the small hole in the steel strap. A molded
plastic wiper arm support is snapped onto the wiper
arm strap where it exits the channel. The entire
wiper arm has a satin black finish applied to all of
its visible surfaces.
Fig. 7 Rear Washer Nozzle Remove/Install
1 - NOZZLE
2 - ROOF PANEL
3 - HEADLINER HOSEFig. 8 Rear Wiper Arm
1 - HOOK
2 - STRAP
3 - CHANNEL
4 - HINGE PIN
5 - COVER
6 - PIVOT END
7 - TENSION SPRING
8 - SUPPORT
KJREAR WIPERS/WASHERS 8R - 37
REAR WASHER NOZZLE (Continued)

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the rear wiper arm from the rear
wiper motor output shaft. (Refer to 8 - ELECTRI-
CAL/REAR WIPERS/WASHERS/REAR WIPER ARM
- REMOVAL).
(3) Using a small thin-bladed tool, gently pry at
the notch in the base of the rear wiper motor output
shaft bezel to unsnap the nut cover from the bezel
(Fig. 16).Be certain to take proper precautions
to protect the outer tailgate panel and its paint
finish from damage during this procedure.
(4) Remove the nut that secures the rear wiper
motor output shaft to the outer swing gate panel
(Fig. 16).
(5) Remove the bezel and gasket from the rear
wiper motor output shaft.
(6) Remove the trim panel from the tailgate inner
panel. (Refer to 23 - BODY/SWING GATE/TRIM
PANEL - REMOVAL).
(7) Disconnect the tailgate wire harness connector
for the flip-up glass ajar switch from the flip-up glass
latch connector receptacle.
(8) Disconnect the tailgate wire harness connector
for the rear wiper motor from the motor connector
receptacle (Fig. 17).
(9) Loosen the two screws that secure the rear
wiper motor mounting bracket to the top of the tail-
gate inner panel.
(10) Slide the rear wiper motor and mounting
bracket back far enough to disengage the two mount-ing screws from the keyed slots in the top of the tail-
gate inner panel.
(11) Remove the rear wiper motor and mounting
bracket from the tailgate as a unit.
INSTALLATION
(1) Position the rear wiper motor and bracket into
the tailgate as a unit (Fig. 17).
(2) Insert the rear wiper motor output shaft
through the hole in the tailgate outer panel and
engage the two mounting screws into the keyed slots
in the top of tailgate inner panel.
(3) From the outside of the tailgate, center the
rear wiper motor output shaft in the tailgate outer
panel clearance hole and install the gasket and bezel
over the centered shaft (Fig. 16).
(4) Install and tighten the nut that secures the
rear wiper motor output shaft to the outer tailgate
panel. Tighten the nut to 5 N´m (43 in. lbs.).
(5) From the inside of the tailgate, tighten the two
screws that secure the rear wiper motor mounting
bracket to the top of the tailgate inner panel. Tighten
the screws to 6 N´m (57 in. lbs.).
(6) Reconnect the tailgate wire harness connector
for the rear wiper motor to the motor connector
receptacle.
Fig. 16 Rear Wiper Motor Output Shaft Nut
Remove/Install
1 - BEZEL AND GASKET
2 - OUTPUT SHAFT
3 - TAILGATE OUTER PANEL
4 - NUT
5 - NUT COVER
Fig. 17 Rear Wiper Motor Remove/Install
1 - KEYED SLOT (2)
2 - SWING GATE INNER PANEL
3 - SCREW (2)
4 - REAR WIPER MOTOR ELECTRICAL CONNECTOR
5 - REAR WIPER MOTOR
8R - 42 REAR WIPERS/WASHERSKJ
REAR WIPER MOTOR (Continued)

ENGINE - 3.7L
TABLE OF CONTENTS
page page
ENGINE - 3.7L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION..............7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE..............8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......8
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION.........9
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS..........9
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............10
REMOVAL.............................10
INSTALLATION.........................11
SPECIFICATIONS
TORQUE............................12
3.7L ENGINE.........................12
SPECIAL TOOLS
3.7L ENGINE.........................15
AIR CLEANER ELEMENT
REMOVAL - 3.7L........................19
INSTALLATION - 3.7L....................19
CYLINDER HEAD - LEFT
DESCRIPTION - VALVE GUIDES...........19
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................19
DIAGNOSIS AND TESTING - CYLINDER
HEAD GASKET.......................19
REMOVAL.............................20
CLEANING............................22
INSTALLATION.........................22
CAMSHAFT(S)
DESCRIPTION.........................23
REMOVAL.............................24
INSTALLATION.........................25
CYLINDER HEAD COVER(S)
DESCRIPTION.........................25
REMOVAL.............................25INSTALLATION.........................26
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................26
STANDARD PROCEDURE - REFACING......26
REMOVAL.............................27
INSTALLATION.........................28
ROCKER ARM
DESCRIPTION.........................29
VALVE GUIDE SEALS
DESCRIPTION.........................29
VALVE SPRINGS
DESCRIPTION.........................29
REMOVAL.............................29
INSTALLATION.........................29
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD........30
DESCRIPTION - VALVE GUIDES..........30
DESCRIPTION........................30
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................30
DIAGNOSIS AND TESTING - CYLINDER
HEAD GASKET.......................30
REMOVAL.............................31
CLEANING............................31
INSPECTION..........................32
INSTALLATION.........................32
CAMSHAFT(S)
DESCRIPTION.........................33
REMOVAL.............................33
INSTALLATION.........................33
CYLINDER HEAD COVER(S)
REMOVAL.............................34
INSTALLATION.........................34
INTAKE/EXHAUST VALVES & SEATS
STANDARD PROCEDURE - REFACING......34
REMOVAL.............................35
INSTALLATION.........................36
ROCKER ARM
DESCRIPTION.........................37
REMOVAL.............................37
INSTALLATION.........................37
VALVE GUIDE SEALS
DESCRIPTION.........................38
VALVE SPRINGS
DESCRIPTION.........................38
REMOVAL.............................38
INSTALLATION.........................38
KJENGINE - 3.7L 9 - 1

DESCRIPTION SPECIFICATION
VALVE TIMING
Intake
Opens (ATDC) 3.6É
Closes (ATDC) 247.1É
Duration 243.5É
Exhaust
Opens (BTDC) 232.5É
Closes (ATDC) 21.2É
Duration 253.70É
Valve Overlap 17.6É
VA LV E S
Face Angle 45É - 45.5É
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake 0.018 - 0.069 mm
(0.0008 - 0.0028 in.)
Exhaust 0.047 - 0.098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem -
to -
Guide Clearance
(Rocking
Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)DESCRIPTION SPECIFICATION
Valve Lift (Zero Lash)
Intake 12.00 mm (0.472 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Lenght (Approx)
Intake and Exhaust 48.92 mm (1.9260 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 361.0 - 399.0 N @ 40.12
mm
(81.15 - 89.70 lbs. @
1.5795 in.)
Spring Force (Valve
Open)
Intake and Exhaust 984.0 - 1076.0 N @
28.12 mm
221.2 - 241.9 lbs. @
1.107 in.)
Number of Coils
Intake and Exhaust 7.30
Wire Diameter
Intake and Exhaust 4.77 ý 3.80mm
(0.1878 - 0.1496 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
Nominal
Intake 41.11 mm (1.619 in.)
Exhaust 41.13 mm (1.619 in.)
CYLINDER HEAD
Gasket Thickness
(Compressed) 0.7 mm (0.0276 in.)
Valve Seat Angle 44.5É - 45.0É
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
9 - 14 ENGINE - 3.7LKJ
ENGINE - 3.7L (Continued)

AIR CLEANER ELEMENT
REMOVAL - 3.7L
Housing removal is not necessary for element (fil-
ter) replacement.
(1) Pry up 2 spring clips (Fig. 3) from front of
housing cover (spring clips retain cover to housing).
(2) Release housing cover from 4 locating tabs
located on rear of housing, and remove cover.
(3) Remove air cleaner element (filter) from hous-
ing.
(4) Clean inside of housing before replacing ele-
ment.
INSTALLATION - 3.7L
(1) Install element into housing.
(2) Position housing cover into housing locating
tabs.
(3) Pry up spring clips and lock cover to housing.
If any air filter, air resonator, air intake tubes or
air filter housing clamps had been loosened or
removed, tighten them to 5 N´m (40 in. lbs.) torque.
CYLINDER HEAD - LEFT
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and
are pressed into the cylinder head. The guides are
not replaceable or serviceable, and valve guide ream-
ing is not recommended. If the guides are worn
beyond acceptable limits, replace the cylinder heads.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) Turn engine off and let set for a few minutes
before restarting. Repeat this several times after
engine has reached normal operating temperature.
(4) Low oil pressure.
(5) The oil restrictor in cylinder head gasket or the
oil passage to the cylinder head is plugged with
debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster.
²Check lash adjusters for sponginess while
installed in cylinder head and cam on camshaft at
base circle. Depress part of rocker arm over adjuster.
Normal adjusters should feel very firm. Spongy
adjusters can be bottomed out easily.
²Remove suspected lash adjusters, and replace.
²Before installation, make sure adjusters are at
least partially full of oil. This can be verified by little
or no plunger travel when lash adjuster is depressed.
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Fig. 3 AIR CLEANER ELEMENT - 3.7L
1 - AIR INTAKE HOSE
2 - HOSE CLAMP
3 - COVER
4 - CLIPS (2)
KJENGINE - 3.7L 9 - 19

Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the left side
exhaust manifold.
(4) Drain the engine coolant. Refer to COOLING
SYSTEM.
(5) Lower the vehicle.
(6) Remove the intake manifold. Refer to proce-
dure in this section.
(7) Remove the cylinder head cover. Refer to proce-
dure in this section.
(8) Remove the fan shroud and fan blade assembly.
Refer to COOLING SYSTEM.
(9) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(10) Remove the power steering pump and set
aside.
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark (Fig. 4).
(12) Verify the V6 mark on the camshaft sprocket
is at the 12 o'clock position (Fig. 5). Rotate the crank-
shaft one turn if necessary.
(13) Remove the crankshaft damper. Refer to Pro-
cedure.
(14) Remove the timing chain cover. Refer to pro-
cedure.
Fig. 4 Engine Top Dead Center
1 - TIMING CHAIN COVER
2 - CRANKSHAFT TIMING MARKS
9 - 20 ENGINE - 3.7LKJ
CYLINDER HEAD - LEFT (Continued)

(21) Remove the cylinder head retaining bolts.
(22) Remove the cylinder head and gasket. Discard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components (Fig. 8). (Refer
to 9 - ENGINE - STANDARD PROCEDURE)
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced. The M8 head
bolts, should not be reused. Use new M8 bolts.
Necking can be checked by holding a straight edge
against the threads. If all the threads do not contact
the scale, the bolt should be replaced (Fig. 9).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Clean the cylinder head and cylinder block
mating surfaces (Fig. 10).(2) Position the new cylinder head gasket on the
locating dowels.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Position the cylinder head onto the cylinder
block. Make sure the cylinder head seats fully over
the locating dowels.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
Fig. 7 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig. 8 Proper Tool Usage For Surface Preparation
1 - PLASTIC/WOOD SCRAPER
Fig. 9 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
9 - 22 ENGINE - 3.7LKJ
CYLINDER HEAD - LEFT (Continued)

NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Remove the camshaft bearing caps and the
camshaft.
INSTALLATION
(1) Lubricate camshaft journals with clean engine
oil.
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 o'clock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Position the camshaft into the cylinder head.
(3) Install the camshaft bearing caps, hand tighten
the retaining bolts.
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
(4) Working in ó turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 14).(5) Torque the camshaft bearing cap retaining
bolts to 11 N´m (100 in. lbs.).
(6) Position the camshaft drive gear into the tim-
ing chain aligning the V6 mark between the two
marked chain links (Two links marked during remov-
al).
(7) Using Special Tool 8428 Camshaft Wrench,
rotate the camshaft until the camshaft sprocket
dowel is aligned with the slot in the camshaft
sprocket. Install the sprocket onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oil from bolt, then install the
camshaft sprocket retaining bolt and hand tighten.
(9) Remove Special Tool 8379 timing chain wedge.
(10) Using Special Tool 6958 spanner wrench with
adapter pins 8346, torque the camshaft sprocket
retaining bolt to 122 N´m (90 ft. lbs.).
(11) Install the cylinder head cover.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of single layer
stamped steel, and are not interchangable from side-
to-side (Fig. 15).
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the resonator assemble and air inlet
hose.
(3) Disconnect injector connectors and un-clip the
injector harness.
(4) Route injector harness in front of cylinder head
cover.
(5) Disconnect the left side breather tube and
remove the breather tube.
(6) Remove the cylinder head cover mounting bolts
(Fig. 16).
(7) Remove cylinder head cover and gasket.
NOTE: The gasket may be used again, providing no
cuts, tears, or deformation has occurred.
Fig. 14 Camshaft Bearing Caps Tightening
Sequence
KJENGINE - 3.7L 9 - 25
CAMSHAFT(S) (Continued)