transmission oil JEEP LIBERTY 2002 KJ / 1.G Owner's Guide

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch Relay . . . 8Wa-10-11, 13, 22,
26
A/C Compressor Clutch.............. 8Wa-10-26
Auto Shut Down Relay...... 8Wa-10-10, 12, 19, 22
Battery....................... 8Wa-10-10, 12
Blower Motor Relay........... 8Wa-10-10, 12, 14
Blower Motor..................... 8Wa-10-14
Body Control Module................ 8Wa-10-23
Cabin Heater Relay........... 8Wa-10-13, 22, 26
Cabin Heater...................... 8Wa-10-26
Camshaft Position Sensor............ 8Wa-10-22
Capacitor...................... 8Wa-10-19, 21
Circuit Breaker No. 1............... 8Wa-10-16
Circuit Breaker No. 3 (JB)........... 8Wa-10-27
Clutch Interlock Switch.............. 8Wa-10-28
Clutch Switch Override Relay......... 8Wa-10-28
Coil On Plug No. 1................. 8Wa-10-21
Coil On Plug No. 2................. 8Wa-10-21
Coil On Plug No. 3................. 8Wa-10-21
Coil On Plug No. 4................. 8Wa-10-21
Coil On Plug No. 5................. 8Wa-10-21
Coil On Plug No. 6................. 8Wa-10-21
Coil Rail......................... 8Wa-10-19
Controller Antilock Brake . 8Wa-10-10, 11, 12, 13, 14
Daytime Running Lamp Relay........ 8Wa-10-16
Defogger Relay.................... 8Wa-10-24
EGR Solenoid..................... 8Wa-10-22
Engine Control Module.............. 8Wa-10-22
Fuel Heater Relay............... 8Wa-10-13, 18
Fuel Heater....................... 8Wa-10-18
Fuel Injector No. 1................. 8Wa-10-20
Fuel Injector No. 2................. 8Wa-10-20
Fuel Injector No. 3................. 8Wa-10-20
Fuel Injector No. 4................. 8Wa-10-20
Fuel Injector No. 5................. 8Wa-10-20
Fuel Injector No. 6................. 8Wa-10-20
Fuel Pressure Solenoid.............. 8Wa-10-22
Fuel Pump Module................. 8Wa-10-26
Fuel Pump Relay................ 8Wa-10-11, 26
Fuse 1.................. 8Wa-10-10, 12, 14, 25
Fuse 2.................. 8Wa-10-10, 12, 14, 15
Fuse 3.................. 8Wa-10-10, 12, 16, 25
Fuse 4..................... 8Wa-10-10, 12, 14
Fuse 5.................. 8Wa-10-10, 12, 17, 18
Fuse 6............... 8Wa-10-10, 12, 19, 22, 24
Fuse 7..................... 8Wa-10-10, 12, 15
Fuse 8..................... 8Wa-10-10, 12, 23
Fuse 9.................. 8Wa-10-10, 12, 13, 24
Fuse 10.............. 8Wa-10-10, 12, 13, 15, 18
Fuse 11.................... 8Wa-10-13, 15, 18
Fuse 12............ 8Wa-10-10, 11, 13, 15, 17, 18
Fuse 13............... 8Wa-10-10, 11, 13, 23, 27
Fuse 14.................... 8Wa-10-11, 13, 23
Fuse 15................. 8Wa-10-11, 13, 25, 27Component Page
Fuse 16................. 8Wa-10-19, 20, 22, 24
Fuse 17.......................... 8Wa-10-24
Fuse 18.......................... 8Wa-10-24
Fuse 19.................... 8Wa-10-11, 13, 24
Fuse 20.......................... 8Wa-10-27
Fuse 21.................... 8Wa-10-11, 13, 26
Fuse 22.......................... 8Wa-10-27
Fuse 24.................... 8Wa-10-11, 26, 29
Fuse 25................. 8Wa-10-11, 13, 14, 29
Fuse 26................. 8Wa-10-12, 19, 20, 22
Fuse 28.......................... 8Wa-10-28
Fuse 29.......................... 8Wa-10-15
Fuse 30.......................... 8Wa-10-24
Fuse 31.......................... 8Wa-10-27
Fuse 32.......................... 8Wa-10-27
Fuse 33.......................... 8Wa-10-16
Fuse 34.......................... 8Wa-10-15
Fuse 36.......................... 8Wa-10-27
Fuse 37.......................... 8Wa-10-29
Fuse 38.......................... 8Wa-10-29
Fuse 39.......................... 8Wa-10-29
Fusible Link................... 8Wa-10-10, 12
G202............................ 8Wa-10-23
Generator.................. 8Wa-10-10, 12, 22
Glow Plug Assembly................ 8Wa-10-18
Glow Plug Relay No. 1......... 8Wa-10-13, 18, 22
Glow Plug Relay No. 2......... 8Wa-10-13, 18, 22
High Beam Relay.................. 8Wa-10-16
Horn Relay....................... 8Wa-10-25
Ignition Switch . . . 8Wa-10-10, 11, 12, 13, 23, 27, 29
Junction Block . . . 8Wa-10-10, 11, 12, 13, 15, 16, 24,
25, 27, 29
Low Beam Relay................... 8Wa-10-25
Oxygen Sensor 1/1 Upstream......... 8Wa-10-19
Oxygen Sensor 1/2 Downstream.... 8Wa-10-19, 20
Oxygen Sensor 2/1 Upstream......... 8Wa-10-19
Oxygen Sensor 2/2 Downstream....... 8Wa-10-20
Oxygen Sensor Downstream Relay . . 8Wa-10-19, 20
Park Lamp Relay.................. 8Wa-10-16
Power Distribution Center . 8Wa-10-2, 3, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25, 26, 27, 28
Power Window Master Switch......... 8Wa-10-29
Powertrain Control Module . . 8Wa-10-11, 19, 26, 28
Radiator Fan Relay.............. 8Wa-10-10, 14
Starter Motor Relay.............. 8Wa-10-23, 28
Starter Motor..................... 8Wa-10-23
Trailer Tow Circuit Breaker..... 8Wa-10-10, 12, 15
Trailer Tow Circuit Breaker.......... 8Wa-10-15
Trailer Tow Connector............... 8Wa-10-15
Trailer Tow Relay.................. 8Wa-10-15
Transmission Control Module . . . 8Wa-10-10, 17, 28
Transmission Control Relay........ 8Wa-10-10, 17
Transmission Solenoid/TRS Assembly . . . 8Wa-10-17
KJ8W-10 POWER DISTRIBUTION8Wa-10-1

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8Wa-30-34
A/C Compressor Clutch Relay..... 8Wa-30-34, 2, 3
A/C High Pressure Switch............ 8Wa-30-29
A/C Low Pressure Switch.......... 8Wa-30-8, 29
A/C Pressure Transducer....... 8Wa-30-11, 23, 12
Accelerator Pedal Position Sensor...... 8Wa-30-27
Auto Shut Down Relay . . 8Wa-30-13, 14, 15, 24, 28,
31, 16, 17, 2
Battery Temperature Sensor........ 8Wa-30-30, 7
Blower Motor Relay................. 8Wa-30-31
Body Control Module.............. 8Wa-30-8, 33
Boost Pressure Sensor............ 8Wa-30-26, 28
Brake Lamp Switch............ 8Wa-30-8, 32, 33
Cabin Heater...................... 8Wa-30-34
Cabin Heater Relay................. 8Wa-30-34
Camshaft Position Sensor....... 8Wa-30-10, 9, 28
Capacitor...................... 8Wa-30-19, 17
Clockspring..................... 8Wa-30-33, 7
Clutch Switch Override Relay.... 8Wa-30-13, 8, 32
Coil On Plug No. 1................. 8Wa-30-19
Coil On Plug No. 2................. 8Wa-30-20
Coil On Plug No. 3................. 8Wa-30-19
Coil On Plug No. 4................. 8Wa-30-20
Coil On Plug No. 5................. 8Wa-30-19
Coil On Plug No. 6................. 8Wa-30-20
Coil Rail......................... 8Wa-30-17
Controller Antilock Brake............ 8Wa-30-33
Crankshaft Position Sensor...... 8Wa-30-10, 9, 27
Data Link Connector.............. 8Wa-30-25, 6
Diagnostic Junction Port........... 8Wa-30-25, 6
EGR Solenoid..................... 8Wa-30-30
Engine Control Module . . 8Wa-30-24, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34, 35, 36
Engine Coolant Temperature Sensor . 8Wa-30-11, 28,
12
Engine Oil Pressure Sensor..... 8Wa-30-11, 28, 12
Evap/Purge Solenoid................. 8Wa-30-2
Fuel Heater....................... 8Wa-30-31
Fuel Heater Relay.................. 8Wa-30-31
Fuel Injector No. 1............... 8Wa-30-18, 36
Fuel Injector No. 2............... 8Wa-30-18, 36
Fuel Injector No. 3............... 8Wa-30-18, 36
Fuel Injector No. 4............... 8Wa-30-18, 36
Fuel Injector No. 5................. 8Wa-30-18
Fuel Injector No. 6................. 8Wa-30-18
Fuel Pressure Sensor............... 8Wa-30-36
Fuel Pressure Solenoid.............. 8Wa-30-31
Fuel Pump Module............. 8Wa-30-30, 4, 5
Fuel Pump Relay.............. 8Wa-30-4, 2, 3, 5
Fuse 2........................... 8Wa-30-23
Fuse 6................... 8Wa-30-24, 28, 31, 2Component Page
Fuse 10.......................... 8Wa-30-35
Fuse 11.......................... 8Wa-30-35
Fuse 12....................... 8Wa-30-31, 33
Fuse 15...................... 8Wa-30-25, 2, 3
Fuse 16...... 8Wa-30-13, 14, 15, 24, 30, 34, 35, 16
Fuse 21.......................... 8Wa-30-34
Fuse 24...................... 8Wa-30-31, 2, 3
Fuse 26.................. 8Wa-30-18, 24, 17, 2
Fuse 28.......................... 8Wa-30-13
G100.................... 8Wa-30-19, 27, 17, 3
G101............................ 8Wa-30-23
G103................. 8Wa-30-15, 23, 31, 34, 16
G104............................ 8Wa-30-27
G111 ............................ 8Wa-30-31
G112 .......................... 8Wa-30-8, 23
G320........................... 8Wa-30-4, 5
Generator.................. 8Wa-30-24, 4, 3, 5
Glow Plug Assembly................ 8Wa-30-35
Glow Plug Relay No. 1.............. 8Wa-30-35
Glow Plug Relay No. 2.............. 8Wa-30-35
Idle Air Control Motor............ 8Wa-30-21, 22
Ignition Switch.................... 8Wa-30-32
Intake Air Temperature Sensor..... 8Wa-30-11, 12
Junction Block........... 8Wa-30-25, 31, 33, 2, 3
Knock Sensor...................... 8Wa-30-8
Leak Detection Pump.............. 8Wa-30-4, 5
Left Speed Control Switch.......... 8Wa-30-33, 7
Manifold Absolute Pressure Sensor . . 8Wa-30-11, 12
Oxygen Sensor 1/1 Upstream...... 8Wa-30-14, 15
Oxygen Sensor 1/2 Downstream . 8Wa-30-13, 14, 15
Oxygen Sensor 2/1 Upstream......... 8Wa-30-16
Oxygen Sensor 2/2 Downstream.... 8Wa-30-13, 16
Oxygen Sensor Downstream Relay . . 8Wa-30-13, 15,
16
Power Distribution Center . . 8Wa-30-13, 14, 15, 23,
24, 28, 30, 31, 34, 35, 16, 17, 2, 3
Power Steering Pressure Switch....... 8Wa-30-23
Powertrain Control Module . . . 8Wa-30-10, 13, 20, 8,
11, 14, 15, 18, 19, 21, 9, 23, 4, 12, 16, 17, 2, 22, 3,
6, 7, 5
Radiator Fan Motor................. 8Wa-30-23
Radiator Fan Relay................. 8Wa-30-23
Right Speed Control Switch......... 8Wa-30-33, 7
Shifter Assembly................. 8Wa-30-8, 32
Speed Control Servo................. 8Wa-30-8
Starter Motor Relay................ 8Wa-30-13
Throttle Position Sensor.......... 8Wa-30-21, 22
Transfer Case Position Sensor.... 8Wa-30-9, 23, 32
Transmission Control Module . . 8Wa-30-10, 8, 22, 6
Transmission Solenoid/Trs Assembly.... 8Wa-30-10
Water In Fuel Sensor............... 8Wa-30-29
KJ8W-30 FUEL/IGNITION SYSTEM8Wa-30-1

SPLICE NUMBER LOCATION FIG.
S151 (Diesel) In Trough Near T/O for Accelerator Pedal Position Sensor 19
S152 In Trough Near T/O for Fuel Injector No.4 2
S153 (2.4L) Near T/O for Coil Rail 11, 12
S153 (3.7L) Near T/O for Idle Air Control Motor 1
S153 (Diesel) In Trough Near T/O for Generator 20, 23
S154 Near T/O for Engine Starter Motor 2, 4, 20
S155 Near T/O for Knock Sensor 1
S156 (2.4L) In Trough Near T/O for C112 13, 14
S156 (3.7L) Near T/O for Powertrain Control Module C1 8
S156 (Diesel) Near T/O for A/C Compressor Clutch 20
S157 Near T/O for Oxygen Sensor 2/2 Downstream N/S
S158 In Trough Near T/O for C112 8
S159 Near T/O for Knock Sensor 1, 8
S160 In T/O for C104 10
S161 Near T/O for Oxygen Sensor 1/2 Downstream 5, 7
S163 In T/O for Transmission Control Module 10
S164 In Trough on Right Rear Side of Engine Compartment 10
S165 In Trough on Right Rear Side of Engine Compartment 10
S167 In T/O for Transmission Control Module 10
S168 Near T/O for Fuel Injector No.6 2
S169 (2.4L) Near T/O for C101 11
S169 (3.7L) Near T/O for Oxygen Sensor 1/1 Upstream 1, 3
S169 (Diesel) Near T/O for Generator 20
S170 Near T/O for C103 8, 13, 16
S175 In Trough on Top of Engine 22, 23
S177 In Trough Near T/O for G100 19
S178 Near T/O for Oxygen Sensor 2/2 Downstream 6
S180 Near T/O for C103 8
S181 In Trough Near T/O for G100 19
S184 Near T/O for Powertrain Control Module C1 8
S200 Near T/O for C201 N/S
S201 Near T/O for Left Instrument Panel Lamp N/S
S204 Near T/O for Data Link Connector N/S
S205 In T/O for C100 N/S
S206 Near T/O for Multifunction Switch C2 N/S
S207 In T/O for C100 N/S
S208 Near T/O for G202 N/S
S210 Near T/O for Left Instrument Panel Lamp N/S
S212 Near T/O for Diagnostic Junction Port N/S
S213 Near T/O for Diagnostic Junction Port N/S
S214 Near T/O for Airbag Control Module C1 (ORC C1) N/S
S215 Near T/O for Multifunction Switch C2 N/S
KJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION8Wa-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

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)

ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron. The block
is a closed deck design with the left bank forward. To
provide high rigidity and improved NVH an
enhanced compacted graphite bedplate (Fig. 31) is
bolted to the block. The block design allows coolant
flow between the cylinders bores, and an internal
coolant bypass to a single poppet inlet thermostat is
included in the cast aluminum front cover.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honingoil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 32).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Use compressed air to clean out:
²The galley at the oil filter adaptor hole.
²The front and rear oil galley holes.
²The feed holes for the crankshaft main bearings.
Fig. 31 CYLINDER BLOCK BEDPLATE
1 - Cylinder Block Bedplate
2 - Crankshaft Position Sensor
3 - Crankshaft Main Bearing Caps
Fig. 32 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
KJENGINE - 3.7L 9 - 39

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506 (Fig. 48), remove the
crankshaft rear oil seal.
INSTALLATION
(1) Position the magnetic seal guide Special Tool
8349±2 (Fig. 49) onto the crankshaft rear face. Then
position the crankshaft rear oil seal onto the guide.(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle (Fig. 50),
with a hammer, tap the seal into place. Continue to
tap on the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) Install the transmission.
Fig. 48 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8506
Fig. 49 Crankshaft Rear Oil Seal Guide Special Tool
8349±2 and Oil
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349±2 GUIDE
Fig. 50 Crankshaft Rear Oil Seal Installation
1 - REAR CRANKSHAFT SEAL
2 - SPECIAL TOOL 8349±1 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
9 - 48 ENGINE - 3.7LKJ

FLEX PLATE
REMOVAL
(1) Remove the transmission.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 95 N´m
(70 ft. lbs.) in the sequence shown (Fig. 51).
(3) Install the transmission.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pistons are made of a high strength aluminum
alloy. The top ring groove is coated with a anti-seize
coating. The connecting rods are made of forged pow-
dered metal, with a ªfractured capº design. A full
floating piston pin is used to attach the piston to the
connecting rod (Fig. 52).
1 Connecting Rod
2 Piston
3 Piston Pin
4 Oil Slinger Slot
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING
Inspect the connecting rod bearings for scoring and
bent alignment tabs. Check the bearings for normal
wear patterns, scoring, grooving, fatigue and pitting.
Replace any bearing that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
necting rod journals. If wear patterns or damage to
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
(1) Wipe the oil from the connecting rod journal.
(2) Lubricate the upper bearing insert and install
in connecting rod.
(3) Use piston ring compressor and Guide Pins
Special Tool 8507 to install the rod and piston assem-
blies. The oil slinger slots in the rods must face front
of the engine. The ªFº's near the piston wrist pin
bore should point to the front of the engine.
(4) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
(5) Install bearing cap and connecting rod on the
journal and tighten bolts to 27 N´m (20 ft. lbs.) plus a
Fig. 51 Flexplate Tightening Sequence
1 - FLEXPLATE
Fig. 52 PISTON AND ROD ASSEMBLY
KJENGINE - 3.7L 9 - 49

CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 66) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 66) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
FRONT MOUNT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the fan blade, fan clutch and fan
shroud. Refer to COOLING SYSTEM for procedure.
(3) Remove the engine oil filter.
(4) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(5) Remove the four (4) cylinder block-to-insulator
mount bolts and the nut from the engine insulator
mount through bolt.
(6) Using the jack, raise the engine high enough to
remove the engine insulator mount through bolt and
the insulator mount (Fig. 67) and (Fig. 68).
Fig. 65 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 66 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 67 Engine Insulator Mount 3.7 Left
1 -MOUNT
2 - NUT
3 - WIRE RETAINER
4 - FASTENER
5 - BOLT
6 - THRU BOLT
9 - 56 ENGINE - 3.7LKJ
STRUCTURAL COVER (Continued)

(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
9s - 4 ENGINEKJ
ENGINE - 2.4L (Continued)