radiator fan JEEP LIBERTY 2002 KJ / 1.G Service Manual

GROUND NUMBER LOCATION FIG.
G201 Under Center Console 33, 37
G202 Left Kick Panel (Black Connector) N/S
G203 Under Center of Instrument Panel N/S
G300 Left Front Seat 35
G301 Under Center Console N/S
G302 Right Front Seat 39
G310 Right Quarter Panel 44, 45
G311 Left Quarter Panel 43
G312 Left Quarter Panel N/S
G320 At Fuel Tank N/S
SPLICES
SPLICE NUMBER LOCATION FIG.
S101 Near T/O to Power Distribution Center N/S
S104 Near T/O to Power Distribution Center N/S
S106 Near T/O for G112 N/S
S107 (Diesel) In T/O for C100 32
S108 Near T/O for C106 29
S109 In Trough Near T/O for Radiator Fan Relay N/S
S110 Near T/O for C106 29
S111 In Trough Near T/O for Radiator Fan Relay N/S
S112 Near T/O to Power Distribution Center N/S
S113 (LHD) In T/O for C100 32
S114 In T/O for C100 N/S
S115 Near T/O for Engine Control Module N/S
S118 In T/O for C100 32
S121 Near T/O to Power Distribution Center N/S
S122 In T/O for Controller Antilock Brake 30
S123 In Trough, Front of Engine Compartment N/S
S124 In T/O for Junction Block C3 N/S
S125 In T/O for Junction Block C3 N/S
S130 Near T/O for Left Headlamp N/S
S131 In T/O for Right Headlamp N/S
S140 Near T/O for Left Front Park/Turn Signal Lamp N/S
S141 Near T/O for Left Fog Lamp N/S
S142 Near T/O for Left Front Park/Turn Signal Lamp N/S
S143 Near T/O for Right Front Park/Turn Signal Lamp N/S
S144 Near T/O for Left Fog Lamp N/S
S145 Near T/O for Right Front Park/Turn Signal Lamp N/S
S146 Near T/O for Right Front Park/Turn Signal Lamp N/S
S151 (2.4L) Near T/O for C110 11, 12
S151 (3.7L) In Trough Near T/O for Fuel Injector No.3 1
8Wa - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONKJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove hood. Mark hood hinge location for
reinstallation.
(3) Remove air cleaner assembly.(4) Remove radiator core support bracket.
(5) Remove fan shroud with electric fan assembly.
(6) Remove mechanical cooling fan.
(7) Remove drive belt.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(8) Remove A/C compressor and secure away from
engine with lines attached.
(9) Remove generator and secure away from
engine.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(10) Remove power steering pump with lines
attached and secure away from engine.
(11) Drain cooling system.
(12) Remove coolant bottle.
(13) Disconnect the heater hoses from the engine.
(14) Disconnect heater hoses from heater core and
remove hose assembly.
(15) Disconnect throttle and speed control cables.
(16) Remove upper radiator hose from engine.
(17) Remove lower radiator hose from engine.
(18) Disconnect the engine to body ground straps
at the left side of cowl.
(19) Disconnect the engine wiring harness at the
following 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
(20) Remove coil over plugs.
(21) Release fuel rail pressure.
(22) Remove fuel rail and secure away from
engine.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(23) Remove the PCV hose.
(24) Remove the breather hoses.
(25) Remove the vacuum hose for the power brake
booster.
(26) Disconnect knock sensors.
(27) Remove engine oil dipstick tube.
(28) Remove intake manifold.
(29) Install engine lift plate.
Fig. 2 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 10 ENGINE - 3.7LKJ
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)

MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cylinder block.
Refer to CRANKSHAFT.
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.002
inch). Compare the measured diameter with the jour-
nal diameter specification (Main Bearing Fitting
Chart). Select inserts required to obtain the specified
bearing-to-journal clearance.
Install the crankshaft into the cylinder block. Refer
to CRANKSHAFT.
Check crankshaft end play. Refer to CHECKING
CRANKSHAFT END PLAY.
CRANKSHAFT MAIN BEARING SELECTION
(1) Service main bearings are available in three
grades. The chart below identifies the three service
grades available.
Crankshaft JOURNAL SIZE
SIZE mm (in.)
MARKING
9R9Size 63.488 - 63.496 mm
(2.4995 - 2.4998 in.)
9S9Size
63.496 - 63.500 mm (2.4998 - 2.4999 in.
9T9Size63.500 - 63.504 mm (2.4999 - 2.501 in.)
Bearing size and application
Bearing
CodeSIze Application
Upper Bearing
A.2.443 - 2.447
mmUse with
Cankshaft size9R9
(.0961 - .0963 in.)
B2.439 - 2.443 mm Use with
crankshaft9S, T9
(0.960 -.o961 in.)
C2.435 - 2.439 mm Use with
carnkshaft9U9
(.0958 - .0960 in.)
Lower Bearing Main919and949
9192.441 - 2.447 mm Use with
carnkshaft9R, S9
(.0961 -.0963 in.)
9292.435 - 2.441 mm Use with
crankshaft9T, U9
(.0958 - .0962 in.)
Crankshaft JOURNAL SIZE
SIZE mm (in.)
MARKING
Lower Main Bearing929and939
9392.429 - 2.435 mm Use with
crankshaft9R, S9
(.0956 - .0958 in.)
9492.423 - 2.429 mm Use with
crankshaft9T, U9
(.0953 - .0956 in.)
Bearing Clearances
Main91, 49
Crankshaft
9R9.004 - .034 mm ( .00015 - .0013 in.)
Crankshaft
9S9.004 - .030 mm ( .00015 - .0011 in.)
Crankshaft
9T9.006 - .032 mm (.0002 - .0012 in.)
Crankshaft
9U9.002 - .032 mm (.00007 -. 0012 in.)
Main92, 39
Crankshaft
9R9.016 - .064 mm (.0 062 - .0025 in.)
Crankshaft
9S9.016 - .042 mm (.00062 - .016 in.)
Crankshaft
9T9.018 - .044 mm (.0007 - .0017 in.)
Crankshaft
9U9.014 - .044 mm (.0005 - .0017 in.)
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove A/C compressor mouning fasteners and
set aside.
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove upper radiator hose.
(6) Disconnect electrical connector for fan mounted
inside radiator shroud.
(7) Remove radiator shroud attaching fasteners.
(8) Remove radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bolt.
9 - 46 ENGINE - 3.7LKJ
CRANKSHAFT MAIN BEARINGS (Continued)

(10) Remove damper using Special Tools 8513
Insert and 1026 Three Jaw Puller (Fig. 45).
(11) Using Special Tool 8511, remove crankshaft
front seal (Fig. 46).INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Using Special Tool 8348 and 8512, install
crankshaft front seal (Fig. 47).
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(3) Install radiator cooling fan and shroud (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(4) Install upper radiator hose.
(5) Install A/C compressor and tighten fasteners to
54 N´m (40 ft. lbs.).
(6) Install accessory drive belt refer (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect negative cable to battery.
Fig. 45 Crankshaft DamperÐRemoval
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 46 Crankshaft Front SealÐRemoval
1 - SPECIAL TOOL 8511
Fig. 47 Crankshaft Front SealÐInstallation
1 - TIMING CHAIN COVER
2 - SPECIAL TOOL 8348
3 - SPECIAL TOOL 8512
KJENGINE - 3.7L 9 - 47
CRANKSHAFT OIL SEAL - FRONT (Continued)

BALANCE SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains. Refer to TIMING CHAIN and SPROCKET.
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.Remove the retaining bolt
from the counterbalance shaft thrust plate (Fig. 96).
(2) Using Special Tool 8641 Counterbalance shaft
remover/installer tool, remove the counterbalance
shaft from the engine (Fig. 97).
INSTALLATION
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.
(1) Coat counterbalance shaft bearing journals
with clean engine oil.
NOTE: The balance shaft is heavy, and care should
be used when installing shaft, so bearings are not
damaged.(2) Using Special Tool 8641 Counterbalance shaft
remover/installer tool, carefully install counterbal-
ance shaft into engine.
(3) Install Counterbalance shaft thrust plate
retaining bolt finger tight.Do not tighten bolt at this
time.
(4) Position the right side of the thrust plate with
the right chain guide bolt, install bolt finger tight.
(5) Torque the thrust plate retaining bolt to 28
N´m (250 in. lbs.).
(6) Remove the chain guide bolt so that guide can
be installed.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove electric cooling fan and fan shroud
assembly.
(4) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(5) Disconnect both heater hoses at timing cover.
(6) Disconnect lower radiator hose at engine.
Fig. 95 Camshaft Sprocket V6 Marks
1 - LEFT CYLINDER HEAD
2 - RIGHT CYLINDER HEAD
9 - 74 ENGINE - 3.7LKJ
VALVE TIMING (Continued)

INSTALLATION
CAUTION: Do not use oil based liquids to clean tim-
ing cover or block surfaces. Use only rubbing alco-
hol, along with plastic or wooden scrapers. Use no
wire brushes or abrasive wheels or metal scrapers,
or damage to surfaces could result.
(1) Clean timing chain cover and block surface
using rubbing alcohol.
CAUTION: The 3.7L uses a special anerobic sealer
instead of a gasket to seal the timing cover to the
engine block, from the factory. For service repairs,
MoparTEngine RTV must be used as a substitute.
(2) Inspect the water passage o-rings for any dam-
age, and replace as necessary.
(3) Apply MopartEngine RTV sealer to front cover
(Fig. 100).
(4) Install cover. Tighten fasteners in sequence as
shown in (Fig. 101) to 54 N´m (40 ft. lbs.).
(5) Install crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(6) Install the A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(7) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION).
(8) Install accessory drive belt tensioner assembly
(Refer to 7 - COOLING/ACCESSORY DRIVE/BELT
TENSIONERS - INSTALLATION).
(9) Install radiator upper and lower hoses.
(10) Install both heater hoses.(11) Install electric fan shroud and viscous fan
drive assembly (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH - INSTALLATION).
(12) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect the battery negative cable.
Fig. 99 Timing Chain Cover Fasteners - Typical
Fig. 100 TIMING COVER SEALANT
1 - TIMING CHAIN COVER
2 - WATER PASSAGE ORING
3 - MOPARTENGINE RTV SEALER
Fig. 101 Timing Chain Cover Fasteners - Typical
9 - 76 ENGINE - 3.7LKJ
TIMING BELT / CHAIN COVER(S) (Continued)

IDLER SHAFT
REMOVAL
(1) Remove the primary and secondary timing
chains and sprockets. Refer to procedure in this sec-
tion.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Using a 12 mm X 1.75 tap, cut threads in the
idler shaft center bore.
(3) Cover the radiator core with a suitable cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Using Special Tool 8517 Slide Hammer, remove
the idler shaft.
INSTALLATION
(1) Thoroughly clean the idler shaft bore.
(2) Position the idler shaft in the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Using the primary idler sprocket retaining bolt
and washer, carefully draw the idler shaft into the
bore until fully seated.
(4) Coat the idler shaft with clean engine oil.
(5) Install the timing chains and sprockets. Refer
to procedure in this section.
TIMING BELT/CHAIN AND
SPROCKET(S
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to COOLING SYS-
TEM for procedures.
(3) Remove right and left cylinder head covers.
Refer to CYLINDER HEAD COVER.
(4) Remove radiator fan shroud. Refer to COOL-
ING SYSTEM for procedure.
(5) Rotate engine until timing mark on crankshaft
damper aligns with TDC mark on timing chain cover
(Fig. 103) (#1 cylinder exhaust stroke) and the cam-
shaft sprocket ªV6º marks are at the 12 o'clock posi-
tion (Fig. 102).
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.).
(6) Remove power steering pump. Refer to STEER-
ING for procedure.
(7) Remove access plug from left and right cylinder
heads for access to chain guide fasteners (Fig. 104).
(8) Remove the oil fill housing to gain access to the
right side tensioner arm fastener.
(9) Remove crankshaft damper and timing chain
cover. Refer to procedures.
(10) Collapse and pin primary chain tensioner.
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chain tensioners.
(12) Remove camshaft position and crankshaft
position sensors (Fig. 105) and (Fig. 106).
KJENGINE - 3.7L 9 - 77

NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) (Refer to 9
- ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
REMOVAL - ENGINE ASSEMBLY
(1) Disconnect the battery negative cable.
(2) Remove hood. Mark hood hinge location for
reinstallation.
(3) Remove air cleaner assembly.
(4) Remove radiator core support bracket.
(5) Remove fan shroud with electric fan assembly.
(6) Remove drive belt.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(7) Remove A/C compressor and secure away from
engine with lines attached.
(8) Remove generator and secure away from
engine.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(9) Remove power steering pump with lines
attached and secure away from engine.
(10) Drain cooling system.
(11) Remove coolant bottle.
(12) Disconnect the heater hoses from the engine.
(13) Disconnect heater hoses from heater core and
remove hose assembly.
(14) Disconnect throttle and speed control cables.
(15) Remove upper radiator hose from engine.
(16) Remove lower radiator hose from engine.
(17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) Disconnect the engine wiring harness at the
following 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
(19) Remove coil over plugs.
(20) Release fuel rail pressure.(21) Remove fuel rail and secure away from
engine.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors.
(26) Secure the left and right engine wiring har-
nesses away from engine.
(27) Raise vehicle.
(28) Disconnect oxygen sensor wiring.
(29) Disconnect crankshaft postion sensor.
(30) Disconnect the engine block heater power
cable, if equipped.
(31) Disconnect the front propshaft at the front
differential and secure out of way.
(32) Remove the starter.
(33) Remove the ground straps from the engine
(34) Disconnect the exhaust pipes at the manifold.
(35) Remove the structural cover, if equipped.
(36) Remove torque convertor bolts, and mark
location for reassembly.
(37) Remove transmission bellhousing to engine
bolts.
(38) Loosen left and right engine mount thru bolts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(39) Lower the vehicle.
(40) Support the transmission with a suitable jack.
(41) Connect a suitable engine hoist to the engine.
CAUTION: The 2.4L engine with manual transmis-
sions, can be removed without removing the man-
ual transmission. Use caution when attempting this
procedure as the clearance is tight.
(42) Remove engine from vehicle.
INSTALLATION - ENGINE ASSEMBLY
(1) Position the engine in the vehicle.
CAUTION: Use caution when installing 2.4L engine
into vehicle equipped with manual transmission, as
clearance is tight.
(2) Install both left and right side engine mounts
into the frame mounts.
(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.
9s - 12 ENGINEKJ
ENGINE - 2.4L (Continued)

(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.
(12) Install the exhaust pipe.
(13) Connect the oxygen sensors.
(14) Lower vehicle.
(15) Connect the knock sensors.
(16) Connect the engine to body ground straps.
(17) Install the power brake booster vacuum hose.
(18) Install the breather hoses.
(19) Install the PCV hose.
(20) Install the fuel rail.
(21) Install the coil over plugs.
(22) Reconnect the engine wiring harness at the
following 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
(23) Connect lower radiator hose.
(24) Connect upper radiator hose.
(25) Connect throttle and speed control cables.
(26) Install the heater hose assembly.
(27) Install coolant recovery bottle.
(28) Install the power steering pump.
(29) Install the generator.
(30) Install the A/C compressor.
(31) Install the drive belt.
(32) Install the fan shroud with the electric fan
assembly.
(33) Install the radiator core support bracket.
(34) Install the air cleaner assembly.
(35) Refill the engine cooling system.
(36) Install the hood.
(37) Check and fill engine oil.
(38) Connect the battery negative cable.
(39) Start the engine and check for leaks.SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type In-Line OHV, DOHC
Number of Cylinders 4
Displacement 2.4 Liters
(148 cu. in.)
Bore 87.5 mm
(3.445 in.)
Stroke 101.0 mm
(3.976 in.)
Compression Ratio 9.4:1
Firing Order 1-3-4-2
Compression Pressure 690 kPa (Minimum)
(100 psi Minimum)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter 87.4924±87.5076 mm
(3.4446±3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons
Piston Diameter 87.463±87.481 mm
(3.4434±3.4441 in.)
Clearance @ 14 mm
(9/16 in.) from bottom of
skirt0.024±0.057 mm
(0.0009±0.0022 in.)
Weight 346±356 grams
(12.20±12.56 oz.)
Land Clearance
(Diametrical)0.614±0.664 mm
(0.024±0.026 in.)
Piston Length 66.25 mm
(2.608 in.)
Piston Ring Groove
Depth No. 14.640±4.784 mm
(0.182±0.188 in.)
Piston Ring Groove
Depth No. 24.575±4.719 mm
(0.180±0.185 in.)
KJENGINE9s-13
ENGINE - 2.4L (Continued)