cable JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(30) Secure the left and right engine wiring har-
nesses away from engine.
(31) Raise vehicle.
(32) Disconnect oxygen sensor wiring.
(33) Disconnect crankshaft postion sensor.
(34) Disconnect the engine block heater power
cable, if equipped.
(35) Disconnect the front propshaft at the front
differential and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.
(36) Remove the starter.
(37) Remove the ground straps from the left and
right side of the block.
(38) Disconnect the right and left exhaust pipes at
the manifolds and from the crossover, and remove
from the vehicle.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
NOTE: For manual transmission vehicles, the trans-
mission must be removed from the vehicle, before
the engine can be removed. The manual transmis-
sion will contact the floorpan before the engine
clears the motor mounts, so it must be removed.
(39) Remove the structural cover.
(40) Remove torque convertor bolts, and mark
location for reassembly.
(41) Remove transmission bellhousing to engine
bolts.
(42) Loosen left and right engine mount thru bolts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(43) Lower the vehicle.
(44) Support the transmission with a suitable jack.
(45) Connect a suitable engine hoist to the engine
lift plate.
(46) Remove engine from vehicle.
INSTALLATION
(1) Position the engine in the vehicle.
(2) Install both left and right side engine mounts
onto engine.
(3) Raise the vehicle.(4) Install the transmission bellhousing to engine
mounting bolts. Tighten the bolts to 41 N´m (30ft.
lbs.).
(5) Tighten the engine mount thru bolts.
(6) Install the torque convertor bolts.
(7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter.
(9) Connect the crankshaft position sensor.
(10) Install the engine block heater power cable, if
equipped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) Install the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) Install the left and right exhaust pipes.
(13) Connect the left and right oxygen sensors.
(14) Lower vehicle.
(15) Remove the engine lift plate.
(16) Connect the knock sensors.
(17) Connect the engine to body ground straps at
the left side of the cowl.
(18) Install the intake manifold.
(19) Install the engine oil dipstick tube.
(20) Install the power brake booster vacuum hose.
(21) Install the breather hoses.
(22) Install the PCV hose.
(23) Install the fuel rail.
(24) Install the coil over plugs.
(25) Connect the engine wiring harness at the fol-
lowing points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(26) Connect lower radiator hose.
(27) Connect upper radiator hose.
(28) Connect throttle and speed control cables.
(29) Install the heater hose assembly.
(30) Install coolant recovery bottle.
(31) Install the power steering pump.
(32) Install the generator.
(33) Install the A/C compressor.
(34) Install the drive belt.
KJENGINE - 3.7L 9 - 11
ENGINE - 3.7L (Continued)

(35) Install the mechanical cooling fan.
(36) Install the fan shroud with the electric fan
assembly.
(37) Install the radiator core support bracket.
(38) Install the air cleaner assembly.
(39) Refill the engine cooling system.
(40) Install the hood.
(41) Check and fill engine oil.
(42) Connect the battery negative cable.
(43) Start the engine and check for leaks.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 Ð
Bearing Cap Bolts 11 Ð 100
Timing Chain CoverÐBolts 54 40 Ð
Connecting Rod CapÐBolts 27 20 Ð
PLUS 90É TURN
Bed PlateÐBolts Refer to Procedure
Crankshaft DamperÐBolt 175 130 Ð
Cylinder HeadÐBolts
M11 Bolts Refer ToProcedure
M8 Bolts - - -
Cylinder Head CoverÐBolts 12 Ð 105
Exhaust ManifoldÐBolts 25 18 Ð
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
FlexplateÐBolts 60 45 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick Tube to Engine
BlockÐBolt 15 Ð 130
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner
ArmÐSpecial
Pin Bolt 17 Ð 150
Hydraulic TensionerÐBolts 28 Ð 250
Timing Chain Primary
TensionerÐBolts28 Ð 250
Timing Drive Idler SprocketÐ
Bolt34 25 Ð
Thermostat HousingÐBolts 12 Ð 105
Water PumpÐBolts 54 40 Ð
3.7L ENGINE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Engine Type 90É SOHC V-6 12-Valve
Displacement 3.7 Liters / 3700 cc
( Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 90.8 mm (3.40 in.)
Compression Ratio 9.1:1
Horsepower 210 BHP @ 5200 RPM
Torque 225 LB-FT @ 4200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-6-5-4-3-2
CYLINDER BLOCK
Cylinder Block Cast Iron
Bore Diameter 93.0   .0075 mm
(3.6619   0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
9 - 12 ENGINE - 3.7LKJ
ENGINE - 3.7L (Continued)

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)

(4) Lubricate the cylinder head bolt threads with
clean engine oil and install the eight M11 bolts.
(5) Coat the four M8 cylinder head bolts with
MopartLock and Seal Adhesivethen install the
bolts.
NOTE: The cylinder head bolts are tightened using
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Tighten the bolts in sequence using the follow-
ing steps and torque values:
²Step 1: Tighten bolts 1±10, 27 N´m (20 ft. lbs.).
²Step 2: Verify that bolts 1±10, all reached 27
N´m (20 ft. lbs.), by repeating step-1 without loosen-
ing the bolts. Tighten bolts 11 thru 14 to 14 N´m (10
ft. lbs.).
²Step 3: Tighten bolts 1±10, 90 degrees (Fig. 11).
²Step 4: Tighten bolts 1±10, 90 degrees, again.
Tighten bolts 11±14, 26 N´m (19 ft. lbs.)
(7) Position the secondary chain onto the camshaft
drive gear, making sure one marked chain link is on
either side of the V6 mark on the gear then using
Special Tool 8428 Camshaft Wrench, position the
gear onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(8) Install the camshaft drive gear retaining bolt.
(9) Install the left side secondary chain guide.(10) Install the cylinder head access plug.
(11) Re-set and Install the left side secondary
chain tensioner.
(12) Remove Special Tool 8429.
(13) Install the timing chain cover.
(14) Install the crankshaft damper. Tighten
damper bolt 175 N´m (130 Ft. Lbs.).
(15) Install the power steering pump.
(16) Install the fan blade assembly and fan
shroud.
(17) Install the cylinder head cover.
(18) Install the intake manifold.
(19) Refill the cooling system
(20) Raise the vehicle.
(21) Install the exhaust pipe onto the left exhaust
manifold.
(22) Lower the vehicle.
(23) Connect the negative cable to the battery.
(24) Start the engine and check for leaks.
CAMSHAFT(S)
DESCRIPTION
The camshafts consist of powdered metal steel
lobes which are sinter-bonded to a steel tube. Four
bearing journals are machined into the camshaft.
Camshaft end play is controlled by two thrust walls
that border the nose piece journal. Engine oil enters
the hollow camshafts at the third journal and lubri-
cates every intake lobe rocker through a drilled pas-
sage in the intake lobe.
Fig. 10 Proper Tool Usage For Surface Preparation
1 - PLASTIC/WOOD SCRAPERFig. 11 CYLINDER HEAD TIGHTENING SEQUENCE
KJENGINE - 3.7L 9 - 23
CYLINDER HEAD - LEFT (Continued)

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)

INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs.).
(3) Install left side breather and connect breather
tube.
(4) Connect injector electrical connectors and injec-
tor harness retaining clips.
(5) Install the resonator and air inlet hose.
(6) Connect negative cable to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. Each
valve is actuated by a roller rocker arm which pivots
on a stationary lash adjuster. All valves use three
bead lock keepers to retain the springs and promote
valve rotation.
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Using a suitable dial indicator measure the
center of the valve seat Total run out must not
exceed 0.051 mm (0.002 in).
(2) Apply a small amount of Prussian blue to the
valve seat, insert the valve into the cylinder head,
while applying light pressure on the valve rotate the
Fig. 15 CYLINDER HEAD COVERS
1 - LEFT SIDE CYLINDER HEAD COVER
2 - RIGHT SIDE CYLINDER HEAD COVER
Fig. 16 CYLINDER HEAD COVER -TYPICAL
1 - SCREWS
2 - CYLINDER HEAD COVER
9 - 26 ENGINE - 3.7LKJ
CYLINDER HEAD COVER(S) (Continued)

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 battery negative cable.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the right 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.
(7) Remove the cylinder head cover. Refer to proce-
dure.
(8) Remove the fan shroud. Refer to COOLING
SYSTEM.
(9) Remove oil fill housing from cylinder head.
(10) Remove accessory drive belt. Refer to COOL-
ING SYSTEM.
(11) Rotate the crankshaft until the damper timing
mark is aligned with TDC indicator mark.
(12) Verify the V6 mark on the camshaft sprocket
is at the 12 o'clock position. Rotate the crankshaft
one turn if necessary.
(13) Remove the crankshaft damper. Refer to pro-
cedure.
(14) Remove the timing chain cover. Refer to pro-
cedure.
(15) Lock the secondary timing chains to the idler
sprocket using Special Tool 8429 Timing Chain Hold-
ing Fixture.NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary timing chain, one link on
each side of the V6 mark on the camshaft drive gear.
(17) Remove the right side secondary chain ten-
sioner. Refer to Timing Chain and Sprockets in this
section.
(18) Remove the cylinder head access plug.
(19) Remove the right side secondary chain guide.
Refer to Timing Chain and Sprockets in this section.
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed
retorque nut to 5 N´m (44 in. lbs.).
(20) Remove the retaining bolt and the camshaft
drive gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with twelve bolts.
(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, do to the design of the cylinder
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. 22). (Refer
to 9 - ENGINE - STANDARD PROCEDURE)
KJENGINE - 3.7L 9 - 31
CYLINDER HEAD - RIGHT (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)

(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 camshaft sprocket bolt,
then install the camshaft sprocket retaining bolt and
hand tighten.
(9) Remove timing chain wedge special tool 8379.
(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 camshaft position sensor.
(12) Install the cylinder head cover.
CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove air cleaner assembly, resonator assem-
bly and air inlet hose.
(3) Drain cooling system, below the level of the
heater hoses. Refer to COOLING SYSTEM.(4) Remove accessory drive belt.
(5) Remove air conditioning compressor retaining
bolts and move compressor to the left.
(6) Remove heater hoses.
(7) Disconnect injector and ignition coil connectors.
(8) Disconnect and remove positive crankcase ven-
tilation (PCV) hose.
(9) Remove oil fill tube.
(10) Un-clip injector and ignition coil harness and
move away from cylinder head cover.
(11) Remove right rear breather tube and filter
assembly.
(12) Remove cylinder head cover retaining bolts.
(13) Remove cylinder head cover.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2) Tighten cylinder head cover bolts and double
ended studs to 12 N´m (105 in. lbs).
(3) Install right rear breather tube and filter
assembly.
(4) Connect injector, ignition coil electrical connec-
tors and harness retaining clips.
(5) Install the oil fill tube.
(6) Install PCV hose.
(7) Install heater hoses.
(8) Install air conditioning compressor retaining
bolts.
(9) Install accessory drive belt
(10) Fill Cooling system
(11) Install air cleaner assembly, resonator assem-
bly and air inlet hose.
(12) Connect battery negative cable.
INTAKE/EXHAUST VALVES &
SEATS
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
Fig. 23 Camshaft Bearing Caps Tightening
Sequence
9 - 34 ENGINE - 3.7LKJ
CAMSHAFT(S) (Continued)

ROCKER ARM
DESCRIPTION
The rocker arms are steel stampings with an inte-
gral roller bearing. The rocker arms incorporate a 2.8
mm (0.11 inch) oil hole in the lash adjuster socket for
roller and camshaft lubrication.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(1) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) For rocker arm removal on cylinder #4, Rotate
the crankshaft until cylinder #1 is at TDC exhaust
stroke.
(3) For rocker arm removal on cylinder #1, Rotate
the crankshaft until cylinder #1 is at TDC compres-
sion stroke.
(4) For rocker arm removal on cylinders #2 and #3,
Rotate the crankshaft until cylinder #1 is at BDC
compression stroke.
(5) For rocker arm removal on cylinders #5 and #6,
Rotate the crankshaft until cylinder #1 is at BDC
exhaust stroke.
(6) Using special tool 8516 Rocker Arm Remover,
press downward on the valve spring, remove rocker
arm (Fig. 29).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm installation on cylinders #4,
Rotate the crankshaft until cylinder #1 is at TDC
exhaust stroke.
(2) For rocker arm installation on cylinder #1,
Rotate the crankshaft until cylinder #1 is at TDC
compression stroke.
(3) For rocker arm installation on cylinders #2 and
#3, Rotate the crankshaft until cylinder #1 is at BDC
compression stroke.
(4) For rocker arm installation on cylinders #5 and
#6, Rotate the crankshaft until cylinder #1 is at BDC
exhaust stroke.
(5) Using special tool 8516 press downward on the
valve spring, install rocker arm (Fig. 30).
(6) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
Fig. 28 Camshaft Bearing Caps Tightening
SequenceFig. 29 Rocker Arm - Removal
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
KJENGINE - 3.7L 9 - 37
INTAKE/EXHAUST VALVES & SEATS (Continued)