electric JEEP LIBERTY 2002 KJ / 1.G User Guide

ELECTRICAL
DESCRIPTION
Three wheel speed sensors are used. The front sen-
sors are mounted to the steering knuckles. The rear
sensor is mounted at the top of the rear axle differ-
ential carrier. Tone wheels are mounted to the out-
board ends of the front axle shafts. The gear type
tone wheel serves as the trigger mechanism for each
sensor.
OPERATION
The sensors convert wheel speed into a small digi-
tal signal. The CAB sends 12 volts to the sensors.
The sensor has an internal magneto resistance
bridge that alters the voltage and amperage of the
signal circuit. This voltage and amperage is changed
by magnetic induction when the toothed tone wheel
passes the wheel speed sensor. This digital signal is
sent to the CAB. The CAB measures the voltage and
amperage of the digital signal for each wheel.
FRONT WHEEL SPEED
SENSOR
REMOVAL
(1) Disconnect the front wheel speed sensor wire
connector that is located on the inboard side of the
respective wheel house.
(2) Raise and support the vehicle.
(3) Remove the tire and wheel assembly.
(4) Remove the caliper adapter. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose with result. Provide a suitable support to hang
the caliper securely.
(5) Remove the disc brake rotor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(6) Remove the wheel speed sensor mounting bolt
to the hub (Fig. 1).
(7) Remove the wheel speed sensor wire from the
hub/bearing (Fig. 1).
(8) Remove the wheel speed sensor wire hold down
from the knuckle (Fig. 1).
(9) Remove the wheel speed sensor wire thru the
wheel well.
(10) Remove the wheel speed sensor from the vehi-
cle.
INSTALLATION
(1) Install the wheel speed sensor to the vehicle.
(2) Install the wheel speed sensor wire thru the
wheel well.
(3) Install the wheel speed sensor wire to the hub/
bearing.
(4) Install the wheel speed sensor wire hold down
to the knuckle.
(5) Install the wheel speed sensor mounting bolt to
the hub. Tighten the mounting bolt to 14 N´m (10
ft.lbs.).
(6) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(7) Install the disc brake caliper adapter. (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Reconnect the front wheel speed sensor wire
connector to the inboard side of the wheel house
being worked on.
Fig. 1 FRONT WHEEL SPEED SENSOR
1 - WHEEL SPEED SENSOR WIRE
2 - WHEEL SPEED SENSOR
3 - ROTOR
4 - WHEEL SPEED SENSOR WIRE HOLD DOWN
5 - 34 BRAKES - ABSKJ

REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove negative battery cable from the bat-
tery.
(3) Pull up on the CAB harness connector release
(Fig. 3)and remove connector.
(4) Remove brake lines from the HCU.
(5) Remove HCU/CAB mounting nuts and bolt
(Fig. 4) and remove HCU/CAB.
INSTALLATION
(1) Install HCU/CAB on the mounting studs.
(2) Install mounting nuts and bolt. Tighten to 11.5
N´m (102 in. lbs.).
(3) Install brake lines to the HCU and tighten to
19 N´m (170 in. lbs.).
(4) Install wiring harness connector to the CAB
and push down on the release to secure the connec-
tor.
(5) Install negative battery cable to the battery.
(6) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).Fig. 3 CAB HARNESS CONNECTOR RELEASE
1 - ABS MODULE
2 - ELECTRICAL CONNECTOR
Fig. 4 HCU/CAB MOUNTING
1 - HCU
2 - CAB
3 - HCU/CAB BRACKET
4 - MOUNTING NUTS AND STUDS
5 - MOTOR
5 - 36 BRAKES - ABSKJ
HCU (HYDRAULIC CONTROL UNIT) (Continued)

BRAKES
TABLE OF CONTENTS
page page
POWER BRAKE BOOSTER
REMOVAL - RHD........................1INSTALLATION - RHD.....................1
POWER BRAKE BOOSTER
REMOVAL - RHD
(1) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Relocate the cruise control servo to gain access
to the booster for removal.
(3) Remove the brake lines from the master cylin-
der.
(4) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(5) Disconnect vacuum hose from booster check
valve.
(6) Remove knee blocker under the steering colum-
n,(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove the brake light switch.(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(8) Remove retaining clip that secures booster
push rod to brake pedal (Fig. 1).
(9) Remove nuts attaching booster to the dash
panel (Fig. 2).(10) In engine compartment, slide booster studs
out of dash panel, tilt booster upward, and remove
booster from engine compartment.
INSTALLATION - RHD
(1) Align and position booster on the dash panel.
(2) Install booster mounting nuts. Tighten nuts
just enough to hold booster in place.
(3) Slide booster push rod onto the brake pedal.
Then secure push rod to pedal pin with retaining
clip.
NOTE: Lubricate the pedal pin with Mopar multi-
mileage grease before installation.
(4) Tighten booster mounting nuts to 39 N´m (29
ft. lbs.).
(5) Install the brake light switch.
(6) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(7) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(8) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
Fig. 1 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 2 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJBRAKES 5s - 1

BRAKES
TABLE OF CONTENTS
page page
POWER BRAKE BOOSTER
REMOVAL - RHD........................1INSTALLATION - RHD.....................1
POWER BRAKE BOOSTER
REMOVAL - RHD
(1) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Relocate the cruise control servo to gain access
to the booster for removal.
(3) Remove the brake lines from the master cylin-
der.
(4) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(5) Disconnect vacuum hose from booster check
valve.
(6) Remove knee blocker under the steering colum-
n,(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove the brake light switch.(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(8) Remove retaining clip that secures booster
push rod to brake pedal (Fig. 1).
(9) Remove nuts attaching booster to the dash
panel (Fig. 2).(10) In engine compartment, slide booster studs
out of dash panel, tilt booster upward, and remove
booster from engine compartment.
INSTALLATION - RHD
(1) Align and position booster on the dash panel.
(2) Install booster mounting nuts. Tighten nuts
just enough to hold booster in place.
(3) Slide booster push rod onto the brake pedal.
Then secure push rod to pedal pin with retaining
clip.
NOTE: Lubricate the pedal pin with Mopar multi-
mileage grease before installation.
(4) Tighten booster mounting nuts to 39 N´m (29
ft. lbs.).
(5) Install the brake light switch.
(6) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(7) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(8) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
Fig. 1 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 2 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJBRAKES 5s - 1

CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The clutch pedal position switch is located under
the instrument panel. It is attached to the clutch
master cylinder push rod (Fig. 10). The wiring har-
ness connection for the switch is made in the engine
compartment (Fig. 10).
The clutch pedal position switch override relay is
located in the Power Distribution Center (PDC).
Refer to PDC cover label for location within PDC.
OPERATION
The clutch pedal position switch is used to prevent
starter motor engagement unless the clutch pedal is
depressed.
4WD Feature:The clutch pedal position switch
override relay will inhibit operation of the position
switch when the vehicle transfer case is in the four±
wheel±drive (4WD) low-range position (only). This
feature will allow operation of the starter motor,
without the need for depressing the clutch pedal, for
certain off-road applications. If any Diagnostic Trou-
ble Codes (DTC's) for either the override relay or
transfer case switch are stored, the override relay
feature will be inhibited.
An input from this switch is also used to either
shut down and/or prevent operation of the speed con-
trol system when the clutch pedal is depressed.
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH
(1) Locate switch 2±wire electrical connector in
engine compartment (Fig. 10). Disconnect wiring at
this point.
(2) Check for switch continuity with an ohmmeter
while operating clutch pedal up and down. Continu-ity should be broken and reapplied each time pedal is
pressed.
(3) If continuity is not present, or is always
present at any pedal position, replace switch. Switch
is not serviced separately. Replace clutch master
cylinder.
Fig. 10 CLUTCH PEDAL POSITION SWITCH
1 - CLUTCH MASTER CYLINDER
2 - CLUTCH PEDAL POSITION SWITCH
3 - CLUTCH PEDAL PIN
4 - MASTER CYLINDER PUSHROD
5 - ELECTRICAL CONNECTION (IN ENGINE COMPARTMENT)
KJCLUTCH 6 - 11

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 3.7L
ENGINE..............................1
DESCRIPTION - COOLING SYSTEM
ROUTING 3.7L ENGINE..................2
DESCRIPTION - HOSE CLAMPS...........2
OPERATION
OPERATION - COOLING SYSTEM.........2
OPERATION - HOSE CLAMPS............3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD)...................3
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS.............................3
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAKS.......................4DIAGNOSIS AND TESTING - COOLING
SYSTEM DIAGNOSIS CHART.............6
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM 3.7L ENGINE.........12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L ENGINE.........12
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING..........12
SPECIFICATIONS
TORQUE............................13
SPECIAL TOOLS
COOLING...........................14
ACCESSORY DRIVE......................15
ENGINE...............................19
TRANSMISSION.........................32
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 3.7L
ENGINE
The cooling system consists of the following items:
²Electric cooling fan - Standard.
²Electric cooling fan and mechanical thermal vis-
cous fan with low disengaged - Heavy duty cooling
only²Radiator
²Hot bottle pressure cap
²Thermostat
²Coolant reserve/overflow system
²Radiator in-tank transmission oil cooler (if
equipped with an automatic transmission)
²Coolant
²Water pump
²Hoses and hose clamps
KJCOOLING 7 - 1

The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
OPERATION - HOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrain control module (PCM) has been
programmed to monitor certain cooling system com-
ponents:
²If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) can be set.
²If an open or shorted condition has developed in
the relay circuit controlling the electric radiator fan,
a Diagnostic Trouble Code (DTC) can be set.
If the problem is sensed in a monitored circuit
often enough to indicated an actual problem, a DTC
is stored. The DTC will be stored in the PCM mem-
ory for eventual display to the service technician.
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC's and to obtain cooling system data,
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRB
scan tool to erase a DTC. Refer to the appropriate
Powertrain Diagnostic Procedures service informa-
tion for operation of the DRB scan tool.
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED
²STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
(1) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(2) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump, or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only. Refer to the group text for information.
Fig. 2 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
KJCOOLING 7 - 3
COOLING (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?1. Refer to (Refer to 25 -
EMISSIONS CONTROL -
DESCRIPTION) for On-Board
Diagnostics and DTC information.
Replace thermostat if necessary.
2. Is the temperature sending unit
connected?2. Check the temperature sensor
connector. (Refer to 7 - COOLING/
ENGINE/ENGINE COOLANT TEMP
SENSOR - DESCRIPTION). Repair
connector if necessary.
3. Is the temperature gauge
operating OK?3. Check gauge operation. Repair
as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.4. Check coolant level in the coolant
pressure botttle and the radiator.
Inspect system for leaks. Repair
leaks as necessary.
5. Improper operation of internal
heater doors or heater controls.5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING)
6. Electric fan functioning when not
required.6. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to group
8W for electric cooling fan and relay
circuit schematic data.
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair.
2. Is the temperature gauge reading
correctly?2. Check gauge. (Refer to Group 8J
- INSTRUMENT CLUSTER). Repair
as necessary.
3. Is the temperature warning
illuminating unnecessarily?3. Check warning lamp operation.
(Refer to Group 8J - INSTRUMENT
CLUSTER).Repair as necessary.
4. Coolant low in coolant pressure
bottle and radiator?4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
7 - 6 COOLINGKJ
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
15. Thermostat partially or
completely shut.15. Check thermostat operation and
replaces necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
DIAGNOSIS AND TESTING).
16. Viscous fan drive not operating
properly.16. Check fan drive operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING).
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING). For
repair, (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
18. Heater core leaking. 18. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
Repair as necessary.
19. Electric fan not functioning. 19. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to Group
8W for electric cooling fan and relay
circuit schematic data.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and
repair if necessary. Refer to Group
8J, Instrument cluster.
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in cooling
system (air will build up in the
cooling system causing the
thermostat to open late).5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
7 - 8 COOLINGKJ
COOLING (Continued)

(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator
is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
ment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE
Drain the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). Remove the thermostat
housing and thermostat. Install the thermostat hous-
ing. Disconnect the radiator upper hose from the
radiator and attach the flushing gun to the hose. Dis-
connect the radiator lower hose from the water
pump. Attach a lead away hose to the water pump
inlet fitting.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
water. When the engine is filled, apply air in short
blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo-
stat housing (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT - REMOVAL).
Install the thermostat and housing with a replace-
ment gasket (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT -INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
BracketÐBolt
2.4L - Ð -
4.7L 41 30 Ð
Automatic Belt Tensioner
PulleyÐ
Bolt
(3.7L) 61 45 Ð
Block HeaterÐBolt
2.4L - Ð -
3.7L 2 Ð 17
Condenser to Radiator Bolts 8 70
Coolant Overflow Bottle to
Plenum mounting bolts - 2.4L
only8.5 75
Coolant Pressure Bottle to
Plenum mounting bolts -3.7L
only8.5 75
Electric Fan to Fan Shroud
bolts5.5 50
Fan Blade Assy. to Viscous
Drive
Bolts 3.7L 23 Ð 210
Fan Shroud to Radiator
Mounting Bolts8Ð70
Radiator Upper Isolator to
Crossmember - Bolts 9.5 Ð 85
Thermostat HousingÐBolts
2.4L - - Ð
4.7L 13 Ð 115
Water PumpÐBolts
2.4L Ð Ð Ð
4.7L 54 40 Ð
KJCOOLING 7 - 13
COOLING (Continued)