Engine number JEEP LIBERTY 2002 KJ / 1.G Manual PDF

Normal vehicle miles or engine misfire can cause a
catalyst to decay. This can increase vehicle emissions
and deteriorate engine performance, driveability and
fuel economy.
The catalyst monitor uses dual oxygen sensors
(O2S's) to monitor the efficiency of the converter. The
dual O2S's sensor strategy is based on the fact that
as a catalyst deteriorates, its oxygen storage capacity
and its efficiency are both reduced. By monitoring
the oxygen storage capacity of a catalyst, its effi-
ciency can be indirectly calculated. The upstream
O2S is used to detect the amount of oxygen in the
exhaust gas before the gas enters the catalytic con-
verter. The PCM calculates the A/F mixture from the
output of the O2S. A low voltage indicates high oxy-
gen content (lean mixture). A high voltage indicates a
low content of oxygen (rich mixture).
When the upstream O2S detects a lean condition,
there is an abundance of oxygen in the exhaust gas.
A functioning converter would store this oxygen so it
can use it for the oxidation of HC and CO. As the
converter absorbs the oxygen, there will be a lack of
oxygen downstream of the converter. The output of
the downstream O2S will indicate limited activity in
this condition.
As the converter loses the ability to store oxygen,
the condition can be detected from the behavior of
the downstream O2S. When the efficiency drops, no
chemical reaction takes place. This means the con-
centration of oxygen will be the same downstream as
upstream. The output voltage of the downstream
O2S copies the voltage of the upstream sensor. The
only difference is a time lag (seen by the PCM)
between the switching of the O2S's.
To monitor the system, the number of lean-to-rich
switches of upstream and downstream O2S's is
counted. The ratio of downstream switches to
upstream switches is used to determine whether the
catalyst is operating properly. An effective catalyst
will have fewer downstream switches than it has
upstream switches i.e., a ratio closer to zero. For a
totally ineffective catalyst, this ratio will be one-to-
one, indicating that no oxidation occurs in the device.
The system must be monitored so that when cata-
lyst efficiency deteriorates and exhaust emissions
increase to over the legal limit, the MIL will be illu-
minated.
DESCRIPTION - TRIP DEFINITION
The term ªTripº has different meanings depending
on what the circumstances are. If the MIL (Malfunc-
tion Indicator Lamp) is OFF, a Trip is defined as
when the Oxygen Sensor Monitor and the Catalyst
Monitor have been completed in the same drive cycle.
When any Emission DTC is set, the MIL on the
dash is turned ON. When the MIL is ON, it takes 3good trips to turn the MIL OFF. In this case, it
depends on what type of DTC is set to know what a
ªTripº is.
For the Fuel Monitor or Mis-Fire Monitor (contin-
uous monitor), the vehicle must be operated in the
ªSimilar Condition Windowº for a specified amount of
time to be considered a Good Trip.
If a Non-Contiuous OBDII Monitor fails twice in a
row and turns ON the MIL, re-running that monitor
which previously failed, on the next start-up and
passing the monitor, is considered to be a Good Trip.
These will include the following:
²Oxygen Sensor
²Catalyst Monitor
²Purge Flow Monitor
²Leak Detection Pump Monitor (if equipped)
²EGR Monitor (if equipped)
²Oxygen Sensor Heater Monitor
If any other Emission DTC is set (not an OBDII
Monitor), a Good Trip is considered to be when the
Oxygen Sensor Monitor and Catalyst Monitor have
been completed; or 2 Minutes of engine run time if
the Oxygen Sensor Monitor or Catalyst Monitor have
been stopped from running.
It can take up to 2 Failures in a row to turn on the
MIL. After the MIL is ON, it takes 3 Good Trips to
turn the MIL OFF. After the MIL is OFF, the PCM
will self-erase the DTC after 40 Warm-up cycles. A
Warm-up cycle is counted when the ECT (Engine
Coolant Temperature Sensor) has crossed 160ÉF and
has risen by at least 40ÉF since the engine has been
started.
DESCRIPTION - COMPONENT MONITORS
There are several components that will affect vehi-
cle emissions if they malfunction. If one of these com-
ponents malfunctions the Malfunction Indicator
Lamp (MIL) will illuminate.
Some of the component monitors are checking for
proper operation of the part. Electrically operated
components now have input (rationality) and output
(functionality) checks. Previously, a component like
the Throttle Position sensor (TPS) was checked by
the PCM for an open or shorted circuit. If one of
these conditions occurred, a DTC was set. Now there
is a check to ensure that the component is working.
This is done by watching for a TPS indication of a
greater or lesser throttle opening than MAP and
engine rpm indicate. In the case of the TPS, if engine
vacuum is high and engine rpm is 1600 or greater
and the TPS indicates a large throttle opening, a
DTC will be set. The same applies to low vacuum if
the TPS indicates a small throttle opening.
All open/short circuit checks or any component that
has an associated limp in will set a fault after 1 trip
with the malfunction present. Components without
KJEMISSIONS CONTROL 25 - 19
EMISSIONS CONTROL (Continued)

MOTOR - OPERATION, IDLE AIR
CONTROL..........................14-35
MOTOR - OPERATION, REAR WIPER.....8R-41
MOTOR - REMOVAL, BLOWER..........24-30
MOTOR - REMOVAL, DRIVE...........23-182
MOTOR - REMOVAL, HEADLAMP
LEVELING..........................8L-36
MOTOR - REMOVAL, IDLE AIR CONTROL . . 14-36
MOTOR - REMOVAL, REAR WIPER......8R-42
MOTOR - REMOVAL, STARTER..........8F-39
MOTOR - REMOVAL, WINDOW..........8N-22
MOTOR, GAS POWERED - STARTER......8F-39
MOTOR RELAY - DESCRIPTION,
BLOWER...........................24-20
MOTOR RELAY - DESCRIPTION,
STARTER ...........................8F-41
MOTOR RELAY - DIAGNOSIS AND
TESTING, BLOWER...................24-21
MOTOR RELAY - INSTALLATION,
BLOWER...........................24-22
MOTOR RELAY - INSTALLATION,
STARTER ...........................8F-43
MOTOR RELAY - OPERATION, BLOWER . . . 24-20
MOTOR RELAY - OPERATION, STARTER . . . 8F-42
MOTOR RELAY - REMOVAL, BLOWER....24-21
MOTOR RELAY - REMOVAL, STARTER....8F-43
MOTOR RESISTOR - DESCRIPTION,
BLOWER...........................24-22
MOTOR RESISTOR - DIAGNOSIS AND
TESTING, BLOWER.....................24-22
MOTOR RESISTOR - INSTALLATION,
BLOWER...........................24-22
MOTOR RESISTOR - OPERATION,
BLOWER...........................24-22
MOTOR RESISTOR - REMOVAL,
BLOWER...........................24-22
MOTOR SWITCH - DESCRIPTION,
BLOWER...........................24-23
MOTOR SWITCH - DIAGNOSIS AND
TESTING, BLOWER...................24-23
MOTOR SWITCH - INSTALLATION,
BLOWER...........................24-23
MOTOR SWITCH - OPERATION, BLOWER . . 24-23
MOTOR SWITCH - REMOVAL, BLOWER . . . 24-23
MOUNT - INSTALLATION, FRONT.........9-57
MOUNT - INSTALLATION, REAR..........9-57
MOUNT - REMOVAL, FRONT.............9-56
MOUNT - REMOVAL, REAR..............9-57
MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER HIGH..........8L-19
MOUNTED STOP LAMP BULB -
REMOVAL, CENTER HIGH..............8L-18
MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER HIGH..........8L-19
MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER HIGH..............8L-19
MOUNTING - STANDARD PROCEDURE,
MATCH .............................22-3
MOUNTING - STANDARD PROCEDURE,
WHEEL............................22-10
MOUNTING BRACKET - INSTALLATION,
PASSENGER AIRBAG.................8O-31
MOUNTING BRACKET - REMOVAL,
PASSENGER AIRBAG.................8O-31
MUFFLER - DESCRIPTION...............11-4
MUFFLER - INSTALLATION
..............11-5
MUFFLER - REMOVAL
..................11-5
MULTI-FUNCTION SWITCH -
DESCRIPTION
.......................8L-46
MULTI-FUNCTION SWITCH - DIAGNOSIS
AND TESTING
.......................8L-50
MULTI-FUNCTION SWITCH -
INSTALLATION
.......................8L-53
MULTI-FUNCTION SWITCH - OPERATION
. . 8L-48
MULTI-FUNCTION SWITCH - REMOVAL
. . . 8L-53
NAME PLATES - INSTALLATION,
EXTERIOR
.........................23-141
NAME PLATES - REMOVAL, EXTERIOR
. . . 23-140
NOISE - DIAGNOSIS AND TESTING, A/C
COMPRESSOR
.......................24-42
NOISE - DIAGNOSIS AND TESTING,
WIND
...............................23-3
NOISE DIAGNOSIS, DIAGNOSIS AND
TESTING - WATER DRAINAGE AND
WIND
.............................23-176
NOISE OR VIBRATION - DIAGNOSIS AND
TESTING, TIRE
.......................22-8NOISE SUPPRESSION GROUND STRAP -
DESCRIPTION, RADIO..................8A-9
NOISE SUPPRESSION GROUND STRAP -
INSTALLATION, RADIO................8A-11
NOISE SUPPRESSION GROUND STRAP -
OPERATION, RADIO..................8A-10
NOISE SUPPRESSION GROUND STRAP -
REMOVAL, RADIO....................8A-10
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS - STANDARD
PROCEDURE, HANDLING...............8O-6
NON-MONITORED CIRCUITS -
DESCRIPTION.......................25-20
NOZZLE - DESCRIPTION, FRONT
WASHER...........................8R-11
NOZZLE - DESCRIPTION, REAR WASHER . 8R-36
NOZZLE - INSTALLATION, FRONT
WASHER...........................8R-11
NOZZLE - INSTALLATION, REAR
WASHER...........................8R-37
NOZZLE - OPERATION, FRONT WASHER . . 8R-11
NOZZLE - OPERATION, REAR WASHER . . . 8R-36
NOZZLE - REMOVAL, FRONT WASHER....8R-11
NOZZLE - REMOVAL, REAR WASHER....8R-36
NUMBER - DESCRIPTION, VEHICLE
IDENTIFICATION....................Intro.-8
NV1500 - ASSEMBLY, MANUAL.........21-13
NV1500 - CLEANING, MANUAL..........21-10
NV1500 - DESCRIPTION, MANUAL........21-1
NV1500 - DISASSEMBLY, MANUAL........21-4
NV1500 - INSPECTION, MANUAL..........21-11
NV1500 - INSTALLATION, EXTENSION
HOUSING SEAL......................21-32
NV1500 - INSTALLATION, MANUAL......21-29
NV1500 - MANUAL...................21-30
NV1500 - OPERATION, MANUAL..........21-1
NV1500 - REMOVAL, EXTENSION
HOUSING SEAL......................21-32
NV1500 - REMOVAL, MANUAL...........21-3
NV1500 - SPECIFICATIONS.............21-30
NV231 - ASSEMBLY, TRANSFER CASE . . . 21-194
NV231 - CLEANING, TRANSFER CASE . . . 21-190
NV231 - DESCRIPTION, TRANSFER CASE . . . 0-3
NV231 - DESCRIPTION, TRANSFER CASE . 21-178
NV231 - DIAGNOSIS AND TESTING,
TRANSFER CASE....................21-180
NV231 - DISASSEMBLY, TRANSFER
CASE.............................21-182
NV231 - INSPECTION, TRANSFER CASE . . 21-190
NV231 - INSTALLATION, TRANSFER
CASE.............................21-205
NV231 - OPERATION, TRANSFER CASE . . 21-179
NV231 - REMOVAL, TRANSFER CASE....21-181
NV231 - TRANSFER CASE.............21-206
NV242 - ASSEMBLY, TRANSFER CASE . . . 21-230
NV242 - CLEANING, TRANSFER CASE . . . 21-227
NV242 - DESCRIPTION, TRANSFER CASE . . . 0-3
NV242 - DESCRIPTION, TRANSFER CASE . 21-215
NV242 - DIAGNOSIS AND TESTING,
TRANSFER CASE....................21-216
NV242 - DISASSEMBLY, TRANSFER
CASE.............................21-218
NV242 - INSPECTION, TRANSFER CASE . . 21-228
NV242 - INSTALLATION, TRANSFER
CASE.............................21-243
NV242 - OPERATION, TRANSFER CASE . . 21-215
NV242 - REMOVAL, TRANSFER CASE....21-217
NV242 - TRANSFER CASE.............21-244
NV242 TRANSFER CASE,
SPECIFICATIONS....................21-244
NV3550 - ASSEMBLY, MANUAL.........21-48
NV3550 - CLEANING, MANUAL..........21-46
NV3550 - DESCRIPTION, MANUAL.......21-33
NV3550 - DISASSEMBLY, MANUAL.......21-35
NV3550 - INSPECTION, MANUAL........21-46
NV3550 - INSTALLATION, EXTENSION
HOUSING BUSHING...................21-74
NV3550 - INSTALLATION, EXTENSION
HOUSING SEAL......................21-74
NV3550 - INSTALLATION, MANUAL......21-70
NV3550 - MANUAL...................21-71
NV3550 - OPERATION, MANUAL
.........21-33
NV3550 - REMOVAL, EXTENSION
HOUSING BUSHING
...................21-73
NV3550 - REMOVAL, EXTENSION
HOUSING SEAL
......................21-74
NV3550 - REMOVAL, MANUAL
..........21-34
ODOMETER - DESCRIPTION
............8J-25ODOMETER - OPERATION..............8J-25
OFF INDICATOR - DESCRIPTION,
OVERDRIVE.........................8J-26
OFF INDICATOR - OPERATION,
OVERDRIVE.........................8J-26
OIL - DESCRIPTION, REFRIGERANT......24-53
OIL - OPERATION, REFRIGERANT........24-54
OIL - STANDARD PROCEDURE, ENGINE....9-61
OIL FILTER - INSTALLATION.............9-63
OIL FILTER - REMOVAL.................9-63
OIL GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE.............9-10
OIL LEAK - DIAGNOSIS AND TESTING,
ENGINE.............................9-60
OIL LEVEL - STANDARD PROCEDURE,
REFRIGERANT.......................24-54
OIL PAN - CLEANING..................9-63
OIL PAN - DESCRIPTION................9-63
OIL PAN - INSPECTION.................9-63
OIL PAN - INSTALLATION...............9-64
OIL PAN - REMOVAL...................9-63
OIL PRESSURE - DIAGNOSIS AND
TESTING, ENGINE.....................9-60
OIL PRESSURE INDICATOR -
DESCRIPTION, LOW..................8J-23
OIL PRESSURE INDICATOR -
OPERATION, LOW....................8J-23
OIL PRESSURE SENSOR/SWITCH -
DESCRIPTION........................9-65
OIL PRESSURE SENSOR/SWITCH -
INSTALLATION........................9-65
OIL PRESSURE SENSOR/SWITCH -
OPERATION..........................9-65
OIL PRESSURE SENSOR/SWITCH -
REMOVAL...........................9-65
OIL PUMP - ASSEMBLY................9-67
OIL PUMP - ASSEMBLY..............21-151
OIL PUMP - CLEANING...............21-150
OIL PUMP - DESCRIPTION............21-147
OIL PUMP - DISASSEMBLY.............9-65
OIL PUMP - DISASSEMBLY............21-149
OIL PUMP - INSPECTION...............9-66
OIL PUMP - INSPECTION.............21-150
OIL PUMP - INSTALLATION.............9-67
OIL PUMP - OPERATION..............21-147
OIL PUMP - REMOVAL.................9-65
OIL PUMP FRONT SEAL - INSTALLATION . 21-152
OIL PUMP FRONT SEAL - REMOVAL....21-152
OIL PUMP VOLUME CHECK - STANDARD
PROCEDURE.......................21-148
OIL SEAL - FRONT - INSTALLATION,
CRANKSHAFT........................9-47
OIL SEAL - FRONT - REMOVAL,
CRANKSHAFT........................9-46
OIL SEAL - REAR - INSTALLATION,
CRANKSHAFT........................9-48
OIL SEAL - REAR - REMOVAL,
CRANKSHAFT........................9-48
ON-BOARD DIAGNOSTICS (OBD) -
DIAGNOSIS AND TESTING...............7-3
ON/OFF RELAY - DESCRIPTION, WIPER . . . 8R-25
ON/OFF RELAY - DIAGNOSIS AND
TESTING, WIPER.....................8R-26
ON/OFF RELAY - INSTALLATION, WIPER . . 8R-26
ON/OFF RELAY - OPERATION, WIPER....8R-25
ON/OFF RELAY - REMOVAL, WIPER......8R-26
OPEN-CIRCUIT VOLTAGE TEST -
STANDARD PROCEDURE...............8F-12
OPENING DIMENSIONS -
SPECIFICATIONS....................23-111
OPENING FLARE MOLDINGS -
INSTALLATION, FRONT WHEEL.........23-145
OPENING FLARE MOLDINGS -
INSTALLATION, REAR WHEEL..........23-145
OPENING FLARE MOLDINGS -
REMOVAL, FRONT WHEEL............23-145
OPENING FLARE MOLDINGS -
REMOVAL, REAR WHEEL.............23-145
OPENING REINFORCEMENT -
INSTALLATION, GRILLE...............23-142
OPENING REINFORCEMENT - REMOVAL,
GRILLE
...........................23-142
OPENING TRIM LACE - INSTALLATION
. . . 23-180
OPENING TRIM LACE - REMOVAL
......23-180
OPENING WEATHERSTRIP -
INSTALLATION, SWING GATE
..........23-186
OPENING WEATHERSTRIP - REMOVAL,
SWING GATE
.......................23-186
KJINDEX 17
Description Group-Page Description Group-Page Description Group-Page

FOREWORD
This manual is designed as a supplement to be used along with the 2002 Liberty service manual,
81-370-02060. It includes information related to the 2.4L gas engine installed in this vehicle by
DaimlerChrysler Corporation. For diagnosis or service procedures relating to other components or systems,
refer to the 2002 Liberty Service Manual.
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. DaimlerChrysler permanently
attaches the label in the engine compartment (Fig.
4). The label cannot be removed without defacing
label information and destroying label.
The label contains the vehicle's emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
The label also contains an engine vacuum sche-
matic. There are unique labels for vehicles built for
sale in the state of California and the country of
Canada. Canadian labels are written in both the
English and French languages.
The VECI label contains the following:
²Engine family and displacement
²Evaporative family
²Emission control system schematic
²Certification application
²Engine timing specifications (if adjustable)
²Idle speeds (if adjustable)
²Spark plug and gap
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
located on the lower left A-pillar and is visible
through the windshield (Fig. 5). The VIN contains 17
characters that provide data concerning the vehicle.
Refer to the VIN decoding chart to determine the
identification of a vehicle.
The Vehicle Identification Number is also
imprinted on the:
²Vehicle Safety Certification Label.
²Frame rail.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
Fig. 4 VECI LABEL LOCATION
1 - RADIATOR SUPPORT
2 - VECI LABEL
Fig. 5 VIN NUMBER LOCATION
1 - A-PILLAR
2 - VIN CODE PLATE
8 INTRODUCTIONKJ

VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV W/O Side Airbags.
8 = MPV With Side Airbags.
4 Gross Vehicle Weight Rating F = 4001 - 5000 lbs.
G = 5001 - 6000 lbs.
5 Vehicle Line K = Liberty 4X2 (LHD)
L = Liberty 4X4 (LHD)
M = Cherokee 4X4 (RHD)
6 Series 3 = Liberty Renegade
4 = Liberty Sport/Cherokee Sport
5 = Liberty Limited/Cherokee Limited
7 Body Style 8 = Sport Utility - 4 Door
8 Engine K = 3.7L 6 cyl MPI Gasoline
1 = 2.4L 4 cyl MPI Gasoline
7 = 2.5L 4 cyl Diesel
9 Check Digit 0 through 9 or X
10 Model Year 2=2002
11 Assembly Plant W = Toledo North Assembly Plant
12 thru 17 Vehicle Build Sequence
VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 6) is
attached to every DaimlerChrysler Corporation vehi-
cle. The label certifies that the vehicle conforms to all
applicable Federal Motor Vehicle Safety Standards.
The label also lists:
²Month and year of vehicle manufacture.
²Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) arebased on a minimum rim size and maximum cold tire
inflation pressure.
²Vehicle Identification Number (VIN).
²Type of vehicle.
²Bar code.
²Month, Day and Hour (MDH) of final assembly.
²Paint and Trim codes.
²Country of origin.
The label is located above the door hinge on the
driver-side A-pillar.
Fig. 6 Vehicle Safety Certification LabelÐTypical
KJINTRODUCTION 9
VEHICLE IDENTIFICATION NUMBER (Continued)