Timing chain JEEP LIBERTY 2002 KJ / 1.G Repair Manual

(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 89).
(8) Install oil pump pick-up tube.(9) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(10) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(11) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a one piece composite mod-
ule that attaches to the cylinder head with fasteners.
The manifold is a long branch design to enhance low
and mid-range torque
OPERATION
The intake manifold delivers air to the combustion
chambers. This air allows the fuel delivered by the
fuel injectors to ignite when the spark plug fire.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
Fig. 87 Oil Pump Sealing - Typical
1 - O-RING
2 - SEALER LOCATION
Fig. 88 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 89 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
KJENGINE9s-51
OIL PUMP (Continued)

EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is made of Hi-Silicone Moly
nodular cast iron for strength and high tempera-
tures. The manifold attaches to the cylinder head.
OPERATION
The exhaust manifold collects the exhaust gasses
exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
the manifold.
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Lower the vehicle.
(3) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(4) Remove the air cleaner bracket (Fig. 91).
(5) Remove the heat shield.
(6) Remove the bolts attaching the manifold to the
cylinder head.
(7) Remove exhaust manifold.
(8) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Clean the manifold mating surfaces.
(2) Install exhaust manifold with a new gasket.
Tighten attaching nuts to 20 N´m (175 in. lbs.).
(3) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(4) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
(5) Install the heat shield.
(6) Install the air cleaner bracket.
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
(1) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove generator drive belt tensioner assem-
bly. (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL)
(3) Remove timing belt front cover bolts, and
remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Hold camshaft sprocket with Special Tool 6847
while removing center bolt.
(4) Remove timing belt idler pulley.
(5) Remove rear cover fasteners and remove cover
from engine.
INSTALLATION
REAR COVER
(1) Install timing belt rear cover and bolts (Fig.
92). Torque bolts to 12 N´m (105 in. lbs).
Fig. 91 AIR CLEANER BRACKET
1 - AIR CLEANER BRACKET
2 - BOLT (2)
KJENGINE9s-53

CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
(2) Install camshaft sprockets, and camshaft target
ring. Hold sprockets with Special Tool 6848 and
tighten center bolt to 101 N´m (75 ft. lbs.).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install accessory drive bracket (Fig. 93).
(6) Install front covers.
FRONT COVER
(1) Install timing belt front covers (Fig. 94).
Tighten fasteners to 7 N´m (60 in. lbs.).
(2) Install generator drive belt tensioner. (Refer to
7 - COOLING/ACCESSORY DRIVE/BELT TEN-
SIONERS - INSTALLATION)
(3) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
Fig. 92 TIMING BELT REAR COVER FASTENERS
1 - OUTER COVER TO REAR COVER FASTENERS (3)
2 - REAR COVER TO CYLINDER HEAD FASTENERS
3 - OUTER COVER TO REAR COVER FASTENERS (3)
4 - INNER COVER TO BLOCK FASTENERS
Fig. 93 ACCESSORY DRIVE BRACKET
1- UPPER TIMING BELT COVER
2- LOWER TIMING BELT COVER
3- BELT TENSIONER
4- ACCESSORY DRIVE BRACKET
Fig. 94 TIMING BELT COVERS
1- UPPER TIMING BELT COVER
2- REAR TIMING BELT COVER
3- LOWER TIMING BELT COVER
4- ACCESSORY DRIVE BRACKET NOT SHOWN
9s - 54 ENGINEKJ
TIMING BELT COVER(S) (Continued)

TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Raise vehicle on hoist.
(3) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELT TENSION-
ERS - REMOVAL)
(4) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(5) Remove air conditioner/generator belt tensioner
and pulley assembly. (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL)
(6) Remove timing belt lower front cover bolts and
remove cover. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - REMOVAL)
(7) Lower vehicle.
(8) Remove bolts attaching timing belt upper front
cover and remove cover. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL)
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(9) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 95).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(10) Install 6 mm Allen wrench into belt tensioner.
Before rotating the tensioner, insert the long end of a
1/8º or 3 mm Allen wrench into the pin hole on the
front of the tensioner (Fig. 96). While rotating the
tensioner counterclockwise, push in lightly on the
1/8º or 3 mm Allen wrench, until it slides into the
locking hole.
(11) Remove timing belt.
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 97).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
Fig. 95 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
KJENGINE9s-55

INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 98).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INSTALLATION - TIMING BELT
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
Fig. 96 Locking Timing Tensioner
1 - 1/8 OR 3mm ALLEN WRENCH
2 - BELT TENSIONER
3 - 6mm ALLEN WRENCH
Fig. 97 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 98 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
9s - 56 ENGINEKJ
TIMING BELT AND SPROCKET(S) (Continued)

(8) Check if the spring tang is within the tolerance
window (Fig. 103). If the spring tang is within the
tolerance window, the installation process is complete
and nothing further is required. If the spring tang is
not within the tolerance window, repeat Steps 5
through 7.
(9) Install timing belt front covers and bolts.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION)
(10) Install air conditioning/generator belt ten-
sioner and pulley. (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS -
INSTALLATION)
(11) Install crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION)
(12) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(13) Install drive belt splash shield.
(14) Install air cleaner housing, upper cover, and
clean air tube.
Fig. 101 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK NUT
5 - SETTING NOTCH
6 - SPRING TANG
Fig. 102 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 103 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
9s - 58 ENGINEKJ
TIMING BELT AND SPROCKET(S) (Continued)

TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 104). Remove both cam
sprockets.
(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 105).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly.
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten.
To properly align tensioner assemblyÐinstall one of
the engine bracket mounting bolts (M10) 5 to 7 turns
into the tensioner's upper mounting location.
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets, torque bolts to 101 N´m (75
ft. lbs.).
(6) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
BALANCE SHAFT
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 106).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
Fig. 104 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 105 TIMING BELT REAR COVER FASTENERS
1 - OUTER COVER TO REAR COVER FASTENERS (3)
2 - REAR COVER TO CYLINDER HEAD FASTENERS
3 - OUTER COVER TO REAR COVER FASTENERS (3)
4 - INNER COVER TO BLOCK FASTENERS
KJENGINE9s-59

INSTALLATION
BALANCE SHAFT TIMING
BALANCE SHAFT INSTALLATION
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
110) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
111).
(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 112).
Fig. 107 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUST SCREW
5 - PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDE
Fig. 108 Drive Chain and Sprockets
1 - NICKEL PLATED LINK AND MARK
2 - GEAR/SPROCKET SCREWS
3 - NICKEL PLATED LINK AND DOT
Fig. 109 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
KJENGINE9s-61
BALANCE SHAFT (Continued)

(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 113).
(6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 114).
(7) Place chain over crankshaft sprocket so that
the plated link of the chain is over the number 1 cyl-
inder timing mark on the balance shaft crankshaft
sprocket (Fig. 114).(8) Place balance shaft sprocket into the timing
chain (Fig. 114) and align the timing mark on the
sprocket (dot) with the (lower) plated link on the
chain.
NOTE: The lower plated link is 8 links from the
upper link.
Fig. 110 Balance Shaft - Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 111 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
Fig. 112 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 113 Balance Shaft Drive
1 - SPROCKET
2 - SPECIAL TOOL 6052
9s - 62 ENGINEKJ
BALANCE SHAFT (Continued)

(9) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
(10) If the sprockets are timed correctly, install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.(11)CHAIN TENSIONING:
(a) Install chain tensioner loosely assembled.
(b) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear
cover. Install and tighten nut/washer assembly to
12 N´m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long or between tensioner and chain.
Push tensioner and shim up against the chain.
Apply firm pressure 2.5±3 Kg (5.5±6.6 lbs.)
directly behind the adjustment slot to take up
all slack.Chain must have shoe radius contact as
shown in (Fig. 115).
(d) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to
12 N´m (105 in. lbs.). Remove shim.
(e) Install carrier covers and tighten screws to
12 N´m (105 in. lbs.).
(12) Install pick-up tube and oil pan.
(13) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 114 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
Fig. 115 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - PIVOT BOLT
KJENGINE9s-63
BALANCE SHAFT (Continued)