reset JEEP LIBERTY 2002 KJ / 1.G Owner's Manual

RIGHT POWER SEAT SWITCH
DESCRIPTION
Vehicles equipped with the power seat option uti-
lize a six-way power seat switch. This six-way power
seat switch features one seat cushion shaped knob,
visible on the outboard seat cushion side shield.
The switch is secured to the back of the seat cush-
ion side shield with two screws. However, the control
knob must be removed before the seat switch can be
removed from the side shield.
The individual switches internal to the power seat
switch cannot be repaired. If one switch is damaged
or faulty, the entire power seat switch unit must be
replaced.
OPERATION
The power seat tracks can be adjusted in six differ-
ent ways using the power seat switches. See the own-
er's manual in the vehicle glove box for more
information on the power seat switch functions and
the seat adjusting procedures.
When a power seat switch control knob or knobs
are actuated, a battery feed and a ground path are
applied through the switch contacts to the power seat
track adjuster motor. The selected adjuster motor
operates to move the seat track through its drive
unit in the selected direction until the switch is
released, or until the travel limit of the seat track is
reached. When the switch is moved in the opposite
direction, the battery feed and ground path to the
motor are reversed through the switch contacts. This
causes the adjuster motor to run in the opposite
direction.
No power seat switch should be held applied in any
direction after the seat track has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
DIAGNOSIS AND TESTING - RIGHT POWER
SEAT SWITCH
For complete circuit diagrams, refer toPower
Seatin Wiring Diagrams.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the power seat switch from the out-
board seat cushion side shield.(3) Use an ohmmeter to test the continuity of the
power seat switch in each switch position. See the
Power Seat Switch Continuity chart (Fig. 8) and
switch (Fig. 9) below. If OK, refer toDiagnosis and
Testing the Power Seat Trackin this section. If
not OK, replace the faulty power seat switch unit.
Fig. 8 SIX-WAY POWER SEAT SWITCH CONTINUITY
Fig. 9 DIAGNOSING POWER SEAT SWITCH
1-UP
2 - REARWARD
3 - DOWN
4 - FORWARD
5 - FRONT RISER SWITCH
6 - CENTER SEAT SWITCH
7 - REAR RISER SWITCH
KJPOWER SEATS 8N - 19

²Intermittent Wipe Mode- The control knob on
the right (wiper) control stalk of the multi-function
switch has five minor detent intermittent wipe posi-
tions. When selected, these switch positions will
cause the front wiper system to operate with one of
five delay intervals between complete wipe cycles.
²Mist Wipe Mode- The right (wiper) control
stalk of the multi-function switch has a momentary
Mist position. When selected, this switch position
will operate the front wipers in a low speed continu-
ous cycle for as long as the switch is held closed,
then will complete the current wipe cycle and park
the front wiper blades near the base of the wind-
shield when the switch is released.
²Washer Mode- When the momentary front
wash position of the right (wiper) control stalk of the
multi-function switch is selected with the front wiper
system operating in a continuous wipe mode, washer
fluid will be dispensed onto the windshield glass
through the washer nozzles for as long as the washer
switch is held closed. When the front washer switch
is actuated with the front wiper system operating in
an intermittent wipe mode, washer fluid is still dis-
pensed until the switch is released; however, the
front wipers will operate in a low speed continuous
cycle from the time the washer switch is closed until
several wipe cycles after the switch is released,
before returning to the selected intermittent wipe
mode.
²Wipe-After-Wash Mode- When the momentary
front wash position of the right (wiper) control stalk
of the multi-function switch is selected with the front
wiper system turned Off, the internal circuitry of the
BCM provides a wipe-after-wash feature. When
selected, this feature will operate the washer pump/
motor and the front wipers for as long as the front
washer switch is held closed, then provide several
additional wipe cycles after the switch is released
before parking the front wiper blades near the base
of the windshield.
OPERATION
The front wiper and washer system is designed to
provide the vehicle operator with a convenient, safe,
and reliable means of maintaining visibility through
the windshield glass. The various components of this
system are designed to convert electrical energy pro-
duced by the vehicle electrical system into the
mechanical action of the wiper blades to wipe the
outside surface of the glass, as well as into the
hydraulic action of the washer system to apply
washer fluid stored in an on-board reservoir to the
area of the glass to be wiped. When combined, these
components provide the means to effectively main-
tain clear visibility for the vehicle operator by remov-
ing excess accumulations of rain, snow, bugs, mud, orother minor debris from the outside windshield glass
surface that might be encountered while driving the
vehicle under numerous types of inclement operating
conditions.
The vehicle operator initiates all front wiper and
washer system functions with the right (wiper) con-
trol stalk of the multi-function switch that extends
from the right side of the steering column, just below
the steering wheel. Rotating the control knob on the
end of the control stalk, selects the Off, Delay, Low,
or High front wiper system operating modes. In the
Delay mode, the control knob also allows the vehicle
operator to select from one of five intermittent wipe
Delay intervals. Pulling the right control stalk down-
wards actuates the momentary front wiper system
Mist mode switch, while pulling the right control
stalk towards the steering wheel actuates the
momentary front washer system switch. The multi-
function switch provides hard wired resistor multi-
plexed inputs to the Body Control Module (BCM) for
all of the front wiper system functions, as well as a
separate hard wired sense input to the BCM for the
front washer system function.
The front wiper and washer system will only oper-
ate when the ignition switch is in the Accessory or
On positions. Battery current is directed from a B(+)
fuse in the Power Distribution Center (PDC) to the
wiper and washer system circuit breaker in the Junc-
tion Block (JB) through a fused ignition switch out-
put (run-acc) circuit. The automatic resetting circuit
breaker then provides battery current through a
fused ignition switch output (run-acc) circuit to the
wiper high/low relay, the wiper on/off relay, and the
park switch within the front wiper motor. A separate
fuse in the JB provides battery current through
another fused ignition switch output (run-acc) circuit
to the multi-function switch. The multi-function
switch circuitry uses this battery feed and a ground
circuit input to directly control the operation and
direction of the reversible electric washer pump/mo-
tor unit. The BCM uses low side drivers to control
front wiper system operation by energizing or de-en-
ergizing the wiper high/low and wiper on/off relays.
The hard wired circuits and components of the
front wiper and washer system may be diagnosed
and tested using conventional diagnostic tools and
procedures. However, conventional diagnostic meth-
ods may not prove conclusive in the diagnosis of the
Body Control Module (BCM), or the inputs to or out-
puts from the BCM that control the front wiper and
washer system operating modes. The most reliable,
efficient, and accurate means to diagnose the BCM,
or the BCM inputs and outputs related to the various
front wiper and washer system operating modes
requires the use of a DRBIIItscan tool. Refer to the
appropriate diagnostic information.
8R - 4 FRONT WIPERS/WASHERSKJ
FRONT WIPERS/WASHERS (Continued)

FRONT WIPER MODULE
DESCRIPTION
The front wiper module bracket is secured with
two nuts below the wiper motor through rubber insu-
lators to two weld studs on the bottom of the cowl
plenum panel beneath the cowl plenum cover/grille
panel (Fig. 14). Two screws secure the top of the
module bracket to the cowl plenum panel through
rubber insulators located on the outboard end of each
pivot bracket. The ends of the wiper pivot shafts that
protrude through dedicated openings in the cowl ple-
num cover/grille panel to drive the wiper arms and
blades are the only visible components of the front
wiper module. The front wiper module consists of the
following major components:
²Bracket- The front wiper module bracket con-
sists of a long tubular steel main member that has a
die cast pivot bracket formation near each end where
the two wiper pivots are secured. A stamped steel
mounting plate for the wiper motor is secured with
welds near the center of the main member. A short
stamped steel tab that extends laterally from one
side of the mounting plate provides a mounting loca-
tion for the wiper motor pigtail wire connector.
²Crank Arm- The front wiper motor crank arm
is a stamped steel unit with a slotted hole on thedriven end that is secured to the wiper motor output
shaft with a nut, and has a ball stud secured to the
drive end.
²Linkage- Two stamped steel drive links con-
nect the wiper motor crank arm to the wiper pivot
lever arms. The right side drive link has a plastic
socket-type bushing on each end. The left side drive
link has a plastic socket-type bushing on one end,
and a plastic sleeve-type bushing on the other end.
The socket-type bushing on one end of each drive
link is snap-fit over the ball stud on the lever arm of
its respective pivot. The left side drive link sleeve-
type bushing end is then fit over the motor crank
arm ball stud, and the other socket-type bushing of
the right side drive link is snap-fit over the exposed
end of the wiper motor crank arm ball stud.
²Motor- The front wiper motor is secured with
three screws to the motor mounting plate near the
center of the wiper module bracket. The wiper motor
output shaft passes through a hole in the module
bracket, where a nut secures the wiper motor crank
arm to the motor output shaft. The two-speed perma-
nent magnet wiper motor features an integral trans-
mission, an internal park switch, and an internal
automatic resetting circuit breaker. A molded plastic
shield covers the top of the motor.
²Pivots- The two front wiper pivots are secured
within the die cast pivot brackets on the outboard
ends of the wiper module main member. The lever
arms that extend from the center of the pivot shafts
each have a ball stud on their end. The upper end of
each pivot shaft where the wiper arms will be fas-
tened each is tapered and serrated with a threaded
stud formation at the tip. The lower ends of the pivot
shafts are installed through lubricated bushings in
the pivot brackets and are secured with snap rings. A
molded plastic shield covers each pivot shaft where it
enters the pivot bracket.
The front wiper module cannot be adjusted or
repaired. If any component of the module is faulty or
damaged, the entire front wiper module unit must be
replaced.
OPERATION
The front wiper module operation is controlled by
the battery current inputs received by the wiper
motor from the wiper on/off and wiper high/low
relays. The wiper motor speed is controlled by cur-
rent flow to either the low speed or the high speed
set of brushes. The park switch is a single pole, sin-
gle throw, momentary switch within the wiper motor
that is mechanically actuated by the wiper motor
transmission components. The park switch alter-
nately closes the wiper park switch sense circuit to
ground or to battery current, depending upon the
position of the wipers on the glass. This feature
Fig. 14 Front Wiper Module
1 - PIVOT BRACKET (2)
2 - MOTOR COVER
3 - MOTOR BRACKET
4 - LINKAGE BUSHING (4)
5 - DRIVE LINK (2)
6 - PIVOT SHAFT (2)
7 - INSULATOR (4)
8 - PIVOT CRANK ARM (2)
9 - PIVOT COVER
10 - MOTOR CRANK ARM
11 - PIGTAIL WIRE CONNECTOR
KJFRONT WIPERS/WASHERS 8R - 15

allows the motor to complete its current wipe cycle
after the wiper system has been turned Off, and to
park the wiper blades in the lowest portion of the
wipe pattern. The automatic resetting circuit breaker
protects the motor from overloads. The wiper motor
crank arm, the two wiper linkage members, and the
two wiper pivots mechanically convert the rotary out-
put of the wiper motor to the back and forth wiping
motion of the wiper arms and blades on the glass.
REMOVAL
(1) Unlatch and open the hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove both front wiper arms from the wiper
pivots. (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS - FRONT/FRONT WIPER ARM - REMOVAL).
(4) Remove the cowl plenum cover/grille panel
from over the cowl plenum. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the headlamp and dash wire har-
ness connector for the front wiper motor from the
motor pigtail wire connector (Fig. 15).
(6) Remove the two screws that secure the front
wiper module to the top of the cowl plenum panel at
the pivot brackets.
(7) Remove the two nuts that secure the front
wiper module to the two weld studs on the bottom of
the cowl plenum panel.
(8) Lift the front wiper module up from the cowl
plenum panel far enough to disengage the two lower
insulators from the weld studs on the bottom of the
plenum panel.(9) Remove the front wiper module from the cowl
plenum panel as a unit.
INSTALLATION
(1) Position the front wiper module to the cowl ple-
num as a unit (Fig. 15).
(2) Lower the front wiper module lower mounting
insulators over the two weld studs on the bottom of
the cowl plenum panel.
(3) Install the two screws that secure the front
wiper module to the top of the cowl plenum panel at
the pivot brackets. Tighten the screw on the driver
side, followed by the screw on the passenger side.
Tighten the screws to 8 N´m (72 in. lbs.).
(4) Install and tighten the two nuts that secure
the front wiper module to the two weld studs on the
bottom of the cowl plenum panel. Tighten the nuts to
8 N´m (72 in. lbs.).
(5) Reconnect the headlamp and dash wire harness
connector for the front wiper motor to the motor pig-
tail wire connector.
(6) Reinstall the cowl plenum cover/grille panel
over the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - INSTALLATION).
(7) Close and latch the hood.
(8) Reinstall both front wiper arms onto the wiper
pivots. (Refer to 8 - ELECTRICAL/FRONT WIPERS/
WASHERS/FRONT WIPER ARM - INSTALLATION).
(9) Reconnect the battery negative cable.
FRONT WIPER/WASHER
SWITCH
DESCRIPTION
The front 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 front 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).
Fig. 15 Front Wiper Module Remove/Install
1 - NUT (2)
2 - SCREW (2)
3 - FRONT WIPER MODULE
4 - STUD (2)
5 - WIRE HARNESS CONNECTOR
8R - 16 FRONT WIPERS/WASHERSKJ
FRONT WIPER MODULE (Continued)

REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use Special Tool
8379 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Remove cylinder head cover. Refer to CYLIN-
DER HEAD COVER in this section.
(2) Set engine to TDC cylinder #1, camshaft
sprocket V6 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V6 mark on the camshaft
sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
(4) Loosen butDO NOTremove the camshaft
sprocket retaining bolt. Leave the bolt snug against
the sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Position Special Tool 8379 timing chain wedge
between the timing chain strands, tap the tool to
securely wedge the timing chain against the ten-
sioner arm and guide (Fig. 12).
(6) Hold the camshaft with Special Tool 8428 Cam-
shaft Wrench, while removing the camshaft sprocket
bolt and sprocket (Fig. 13).
(7) Using Special Tool 8428 Camshaft Wrench,
gently allow the camshaft to rotate 5É clockwise until
the camshaft is in the neutral position (no valve
load).
(8) Starting at the outside working inward, loosen
the camshaft bearing cap retaining bolts 1/2 turn at
a time. Repeat until all load is off the bearing caps.CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
Fig. 12 SECURING TIMING CHAIN TENSIONERS
USING TIMING CHAIN WEDGE Ð Typical
1 - SPECIAL TOOL 8379
2 - CAMSHAFT SPROCKET
3 - CAMSHAFT SPROCKET BOLT
Fig. 13 Special Tool 8428
1 - Camshaft hole
2 - Special Tool 8428
9 - 24 ENGINE - 3.7LKJ
CAMSHAFT(S) (Continued)

(19) Install oil fill housing onto cylinder head.
(20) Refill the cooling system.
(21) Raise the vehicle.
(22) Install the exhaust pipe onto the right
exhaust manifold.
(23) Lower the vehicle.
(24) Reconnect battery negitive cable.
(25) 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.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use special tool 8379
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Remove the cylinder head cover. Refer to CYL-
INDER HEAD COVER in this section.
(2) Set engine to TDC cylinder #1, camshaft
sprocket V6 marks at the 12 o'clock position.
(3) Mark one link on the secondary timing chain
on both sides of the V6 mark on the camshaft
sprocket to aid in installation.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen butDO NOTremove the camshaft
sprocket retaining bolt. Leave bolt snug against
sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Position Special Tool 8379 timing chain wedge
between the timing chain strands. Tap the tool to
securely wedge the timing chain against the ten-
sioner arm and guide.
(6) Remove the camshaft position sensor.
(7) Hold the camshaft with Special Tool 8428 Cam-
shaft Wrench, while removing the camshaft sprocket
bolt and sprocket.
(8) Starting at the outside working inward, loosen
the camshaft bearing cap retaining bolts 1/2 turn at
a time. Repeat until all load is off the bearing caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
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 right side camshaft so that the
camshaft sprocket dowel is near the 10 o'clock
position, 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 1/2 turn increments, tighten the
bearing cap retaining bolts starting with the middle
cap working outward (Fig. 23).
(5) Torque the camshaft bearing cap retaining
bolts to 11 N´m (100 in. lbs.).
KJENGINE - 3.7L 9 - 33
CYLINDER HEAD - RIGHT (Continued)

INSTALLATION
(1) Using a vise, lightly compress the secondary
chain tensioner piston until the piston step is flush
with the tensioner body. Using a pin or suitable tool,
release ratchet pawl by pulling pawl back against
spring force through access hole on side of tensioner.
While continuing to hold pawl back, Push ratchet
device to approximately 2 mm from the tensioner
body. Install Special Tool 8514 lock pin into hole on
front of tensioner (Fig. 107). Slowly open vise to
transfer piston spring force to lock pin.
(2) Position primary chain tensioner over oil pump
and insert bolts into lower two holes on tensioner
bracket. Tighten bolts to 28 N´m (250 in. lbs.).
(3) Install right side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 28
N´m (250 in. lbs.).
CAUTION: The silver bolts retain the guides to the
cylinder heads and the black bolts retain the guides
to the engine block.
(4) Install the left side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
(5) Install left side chain tensioner arm. Apply
MopartLock N, Seal to torxtbolt, tighten bolt to 28
N´m (250 in. lbs.).(6) Install the right side chain guide. Tighten the
bolts to 28 N´m (250 in. lbs.).
(7) Install both secondary chains onto the idler
sprocket. Align two plated links on the secondary
chains to be visible through the two lower openings
on the idler sprocket (4 o'clock and 8 o'clock). Once
the secondary timing chains are installed, position
special tool 8429 to hold chains in place for installa-
tion.
(8) Align primary chain double plated links with
the timing mark at 12 o'clock on the idler sprocket.
Align the primary chain single plated link with the
timing mark at 6 o'clock on the crankshaft sprocket.
(9) Lubricate idler shaft and bushings with clean
engine oil.
NOTE: The idler sprocket must be timed to the
counterbalance shaft drive gear before the idler
sprocket is fully seated.
(10) Install all chains, crankshaft sprocket, and
idler sprocket as an assembly (Fig. 108). After guid-
ing both secondary chains through the block and cyl-
inder head openings, affix chains with a elastic strap
or the equivalent, This will maintain tension on
chains to aid in installation. Align the timing mark
on the idler sprocket to the timing mark on the coun-
terbalance shaft drive gear, then seat idler sprocket
fully (Fig. 109). Before installing idler sprocket bolt,
lubricate washer with oil, and tighten idler sprocket
assembly retaining bolt to 34 N´m (25 ft. lbs.).
Fig. 107 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 108 Installing Idler Gear, Primary and
Secondary Timing Chains
1 - SPECIAL TOOL 8429
2 - PRIMARY CHAIN IDLER SPROCKET
3 - CRANKSHAFT SPROCKET
9 - 80 ENGINE - 3.7LKJ
TIMING BELT/CHAIN AND SPROCKET(S (Continued)

REMOVAL - 2WD
(1) Siphon the power steering fluid from the power
steering reservoir.
(2) Lock the steering wheel to prevent spinning of
the clockspring.
(3) Raise and support the vehicle.
(4) Remove the skid plate from under the front
end to gain access to the gear(Refer to 13 - FRAME
& BUMPERS/FRAME/FRONT SKID PLATE -
REMOVAL).
(5) Remove the tire and wheel assembly.
NOTE: Mark the alignment adjusting cams and tie
rod end jam nuts on the steering gear for easier
installation.
(6) Remove the tie rod end nuts.
(7) Separate tie rod ends from the knuckles with
Puller C-3894-A.
(8) Remove the lower intermediate shaft coupler
bolt and slide the coupler off the gear (Fig. 2).(9) Remove power steering pressure hose bracket
(Fig. 3).
(10) Remove the power steering lines from the
gear (Fig. 2).
(11) Remove the mounting bolts from the gear to
the front cradle (Fig. 3).
(12) Remove the steering gear from the vehicle.
INSTALLATION
INSTALLATION - 4WD
(1) Transfer the tie rod ends to the new steering
gear (if needed).
(2) Install the steering gear to the vehicle.
(3) Install the gear mounting bolts to the front cra-
dle. (Fig. 3). Tighten the gear mounting bolts to 162
N´m (120 ft.lbs.)
(4) Install the power steering lines to the gear
(Fig. 2).
(5) Install the power steering pressure hose
bracket (Fig. 3).
(6) Install the lower coupler bolt and slide the cou-
pler on to the gear (Fig. 2).
(7) Install the tie rod end to the knuckle and
tighten the nuts.
(8) Install the front axle. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/FRONT AXLE - INSTALLA-
TION).
(9) Install the lower control arms. (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
INSTALLATION).
(10) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Install the skid plate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE - INSTAL-
LATION).
(12) Lower the vehicle.
(13) Unlock the steering wheel.
(14) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(15) Reset the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
INSTALLATION - 2WD
(1) Transfer the outer tie rod ends to the new
steering gear (if needed).
(2) Install the steering gear to the vehicle.
(3) Install the gear mounting bolts to the front cra-
dle. (Fig. 3). Tighten the gear mounting bolts to 162
N´m (120 ft.lbs.)
(4) Install the power steering lines to the gear
(Fig. 2).
Fig. 2 COUPLER BOLT
Fig. 3 RACK & PINION
19 - 14 GEARKJ
GEAR (Continued)

(5) Install the power steering pressure hose
bracket (Fig. 3).
(6) Install the lower coupler bolt and slide the cou-
pler on to the gear (Fig. 2).
(7) Install the tie rod end to the knuckle and
tighten the nuts.
(8) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(9) Install the skid plate(Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE - INSTAL-
LATION).(10) Lower the vehicle.
(11) Unlock the steering wheel.
(12) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(13) Reset the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Rack and Pinion Steering
Gear
Gear to Frame Bolts162 120 Ð
Rack and Pinion Steering
Gear
Intermediate Shaft Bolt49 36 Ð
Tie Rod End
Knuckle Nut108 80 Ð
Tie Rod End
Jam Nut75 55 Ð
Power Steering Line
Pressure Line35 25 Ð
Power Steering Line
Return Line35 25 Ð
SPECIAL TOOLS
OUTER TIE ROD END REMOVAL TOOL
Puller C-3894-A
KJGEAR 19 - 15
GEAR (Continued)

LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
STANDARD PROCEDURE - STEERING
LINKAGE............................16TIE ROD END
REMOVAL.............................16
INSTALLATION.........................16
LINKAGE
STANDARD PROCEDURE - STEERING LINKAGE
The tie rod end and ball stud seals should be
inspected during all oil changes. If a seal is damaged,
replace the tie rod.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
TIE ROD END
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
NOTE: Mark the tie rod end jam nuts on the steer-
ing gear for easier installation.
(3) Loosen the tie rod end jam nut (Fig. 1).
(4) Remove the tie rod end nut (Fig. 1).
(5) Seperate the tie rod end from the knuckle
using tool C3894A.
NOTE: Count the number of turns when removing.
(6) Remove the tie rod end from the rack (Fig. 1).
INSTALLATION
(1) Install the tie rod end to the rack to the exact
number of turns that it was removed (Fig. 1).(2) Install the tie rod end to the knuckle. Tighten
the nut to 108 N´m (80 ft.lbs).
(3) Tighten the jam nut to 76 N´m (55 ft.lbs). (Fig.
1).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(5) Reset the toe and center the steering wheel
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
STANDARD PROCEDURE).
Fig. 1 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
19 - 16 LINKAGEKJ