alignment JEEP LIBERTY 2002 KJ / 1.G Manual Online

REMOVAL
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are either clamped together or welded
together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINE.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Raise and support the vehicle.
(2) Disconnect front tailpipe hanger from the insu-
lator (Fig. 5).
(3) Remove the mounting nuts from the muffler to
catalytic converter flange (Fig. 5).
(4) Remove the tailpipe from the rear tailpipe
hanger (Fig. 5).
(5) Remove the muffler and tailpipe assembly from
the vehicle.
INSTALLATION
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-fler. Service replacement mufflers and exhaust
tailpipes are either clamped together or welded
together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINE.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Position muffler and tailpipe assembly into
vehicle.
(2) Install clamp retaining tailpipe to the rear
tailpipe hanger (Fig. 5).DO NOTtighten clamp at
this time.
(3) Install mounting nuts onto the muffler to cata-
lytic converter flange studs (Fig. 5).DO NOTtighten
nuts at this time.
(4) Make sure the exhaust system is in proper
alignment. There should be at least 25mm (1 inch)
clearance between the exhaust components and any
surrounding components.
(5) Tighten muffler to catalytic converter flange
mounting nuts to 28.5 N´m (21 ft. lbs.).
(6) Tighten tailpipe clamp to 48 N´m (35 ft. lbs.).
KJEXHAUST SYSTEM 11 - 5
MUFFLER (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM.............................2
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER.....2
REMOVAL.............................2
INSPECTION...........................3
INSTALLATION..........................3CROSS-OVER PIPE
REMOVAL.............................4
INSTALLATION..........................4
HEAT SHIELDS
DESCRIPTION..........................4
MUFFLER
DESCRIPTION..........................4
REMOVAL.............................4
INSTALLATION..........................5
EXHAUST SYSTEM
DESCRIPTION
The basic exhaust system consists of an engine
exhaust manifold, exhaust down pipe, exhaust pipe,
exhaust heat shield(s), muffler and exhaust tailpipe
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it will transfer objec-
tionable noises originating from the engine to the
body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked orbroken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
KJEXHAUST SYSTEM 11s - 1

2.4L ENGINES
(1) Disconnect the oxygen sensors.
(2) Remove the two bolts and flanged nuts at the
manifold (Fig. 1).
(3) Lower the catalyst assembly and slide out of
the mount at the transmission (if equipped).
(4) Remove the catalyst assembly from the vehicle.
3.7L ENGINES
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(1) Remove the T bolt end of the fastener, from the
clamp.
(2) Spread the clamp, and remove the catalytic
converter from the vehicle.
(3) Discard the clamp (Fig. 2).
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter,
inspect for bulging or other distortion that could be a
result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap-
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
INSTALLATION
(1) Position the catalytic converter onto the
exhaust pipe flange connection. Tighten the nuts to
28 N´m (250 in. lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install the exhaust clamp at the muffler and
catalytic converter connection. Tighten the clamp
nuts to 47 N´m (35 ft. lbs.) torque.
(4) Connect oxygen sensor wiring.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
Fig. 1 2.4L CATALYST ASSEMBLY - 4x4
1- FLANGED NUT
2- CATALYST ASSEMBLY
3- BOLT
4- HANGER
5- NUT
Fig. 2 Catalyst Removal
1 - V-Clamp
2 - Catalytic Converter
3 - Flange
4 - Crossover Pipe
5 - T-Bolt
KJEXHAUST SYSTEM 11s - 3
CATALYTIC CONVERTER (Continued)

(1) Position muffler and tailpipe assembly into
vehicle.
(2) Install clamp retaining tailpipe to the rear
tailpipe hanger.DO NOTtighten clamp at this time.
(3) Install mounting nuts onto the muffler to cata-
lytic converter flange studs.DO NOTtighten nuts at
this time.
(4) Make sure the exhaust system is in proper
alignment. There should be at least 25mm (1 inch)clearance between the exhaust components and any
surrounding components.
(5) Tighten muffler to catalytic converter flange
mounting nuts to 28.5 N´m (21 ft. lbs.).
(6) Tighten tailpipe clamp to 48 N´m (35 ft. lbs.).
11s - 6 EXHAUST SYSTEMKJ
MUFFLER (Continued)

(3) Remove 4 fuel pump module access plate nuts
(Fig. 3).
(4) While applying heat from a heat gun, carefully
pry up fuel pump module access plate. Take care not
to bend plate.
(5) Disconnect flow management valve hose clamp
and hose (Fig. 4) at pump module fitting. Also discon-
nect small recirculation line at top half of manage-
ment valve.
(6) Raise vehicle.
(7) Disconnect opposite end of flow management
valve hose at EVAP canister (Fig. 1).
(8) Remove valve and 2 hoses as an assembly.
INSTALLATION
(1) Raise vehicle.
(2) Attach 2 large hoses and 1 small line to flow
management valve. Position this assembly to top of
fuel tank.
(3) Connect valve hose at EVAP canister.
(4) Lower vehicle.
(5) Attach valve hose and clamp to top of fuel
pump module.
(6) Apply silicone sealant to bottom of fuel pump
module metal access plate.(7) Install fuel pump module metal access plate
and 4 nuts. Tighten nuts to 3 N´m (26 in. lbs.)
torque.
(8) Position carpet and install 2 new cargo clamp
rivets.
FUEL FILTER
DESCRIPTION
The fuel pressure regulator and fuel filter are not
combined on this vehicle. The main fuel filter is
attached to the front of the fuel tank (Fig. 1) and is a
serviceable/replaceable item. Also refer to Inlet Filter
and Fuel Pressure Regulator.
REMOVAL
The main fuel filter is attached to the front of fuel
tank (Fig. 1). Three fuel lines are used at filter.
Fuel tank removal will not be necessary for
fuel filter removal. Access is from rear cargo
area.
WARNING: THE FUEL SYSTEM MAY BE UNDER A
CONSTANT PRESSURE (EVEN WITH THE ENGINE
OFF). BEFORE SERVICING MOST FUEL SYSTEM
COMPONENTS, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL SYS-
TEM PRESSURE RELEASE PROCEDURE.
(1) Release fuel system pressure.
(2) Four cargo holdown clamps are located inside
vehicle on floor of rear cargo area. Two of these four
clamps must be removed. Remove 2 rearward
mounted clamps by drilling out clamp rivets.
(3) Fold carpeting forward to gain access to fuel
pump module access plate (Fig. 5).
(4) Remove 4 fuel pump module access plate nuts
(Fig. 5).
(5) While applying heat from a heat gun, carefully
pry up metal fuel pump module access plate. Take
care not to bend plate.
(6) Clean top of fuel pump module area around
fuel line connection points.
(7) Disconnect 2 fuel lines at fuel pump module
(Fig. 6) by pressing on tabs at side of fitting.
(8) Raise vehicle.
(9) Place drain pan under fuel filter.
(10) A third fuel line is attached to bottom of filter
(Fig. 7). The disconnection point for this 3rd line is
approximately 1 foot towards front of vehicle. Clean
fuel line connection point before disconnection. Dis-
connect by pressing on tabs at side of fitting.
(11) Disconnect 3rd fuel line from body retention
clip. Place a small screwdriver into side of clip and
twist for removal.
Fig. 4 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)
KJFUEL DELIVERY 14 - 7
FLOW MANAGEMENT VALVE (Continued)

(b) The sides of pump module are equipped with
tension springs (Fig. 29). These springs hold mod-
ule to bottom of fuel tank into 2 formed guides
(Fig. 30). Release module assembly from these 2
guides by sliding toward right side of fuel tank.
(c) Lift assembly from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
pump module gasket must be replaced.
(1) Position lower section of fuel pump module
assembly into fuel tank.
(2) The bottom of fuel tank has 2 formed guides.
Lock module assembly into these 2 guides by sliding
toward left side of fuel tank.
(3) Push down on plastic tab to lock module to fuel
tank guides.
(4) Connect fuel supply line to bottom of upper
pump module section.
(5) Connect fuel pressure regulator to bottom of
upper pump module section.
(6) Connect electrical connector to bottom of upper
pump module section.
(7) Position pump module into fuel tank. Notch on
module must be facing rear of tank.(8) Position lock ring to module. Tap lockring
using a brass drift and hammer (clockwise) until
rotated up to built-on stops.
(9) Attach (snap on) 2 fuel filter fuel lines to top of
fuel pump module.
(10) Connect hoses/lines to ORVR components.
(11) Fill fuel tank with fuel.
(12) Start engine and check for fuel leaks.
(13) Apply silicone sealant to bottom of fuel pump
module metal access plate.
(14) Install fuel pump module metal access plate
and 4 nuts. Tighten nuts to 3 N´m (26 in. lbs.)
torque.
(15) Position carpet and install 2 new cargo clamp
rivets into each cargo holdown clamp.
Fig. 25 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
Fig. 26 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)
KJFUEL DELIVERY 14 - 19
FUEL PUMP MODULE (Continued)

of the firing of the fuel injectors. It isnot usedas a
fuel pressure regulator. The fuel pressure regulator is
not mountedto the fuel rail on any engine. It is
located on the fuel tank mounted fuel pump module.
Refer to Fuel Pressure Regulator for additional infor-
mation.
The fuel rail is not repairable.
A quick-connect fitting with a safety latch is used
to attach the fuel line to the fuel rail.
3.7L
High pressure fuel from the fuel pump is routed to
the fuel rail. The fuel rail then supplies the neces-
sary fuel to each individual fuel injector.
A quick-connect fitting with a safety latch is used
to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
REMOVAL
2.4L
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
The fuel rail can be removed without removing the
intake manifold if the following procedures are fol-
lowed.(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body.
(5) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(6) Remove necessary vacuum lines at throttle
body.
(7) Drain engine coolant and remove thermostat
and thermostat housing.
(8) Remove PCV hose and valve at valve cover.
(9) Remove 3 upper intake manifold mounting
bolts (Fig. 35), but only loosen 2 lower bolts about 2
turns.
(10) Disconnect 2 main engine harness connectors
at rear of intake manifold (Fig. 34).
(11) Disconnect 2 injection wiring harness clips at
harness mounting bracket (Fig. 35).
(12) Disconnect electrical connectors at all 4 fuel
injectors. To remove connector refer to (Fig. 37). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(13) Remove 2 injection rail mounting bolts (Fig.
31).
Fig. 34 MAP SENSOR LOCATION-2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
5 - ELECTRICAL CONNECTOR
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 35 FUEL RAIL MOUNTING-2.4L
1 - FUEL RAIL
2 - INJECTION HARNESS CLIPS
3 - LOWER MOUNTING HOLES
4 - UPPER MOUNTING HOLES
5 - INTAKE MANIFOLD
14 - 22 FUEL DELIVERYKJ
FUEL RAIL (Continued)

(11) Remove module lockring (Fig. 40) using a
brass drift and hammer (counter-clockwise).
(12) Carefully lift upper section of pump module
from fuel tank a few inches(lift upper section
from tank very slowly until rubber gasket can
be retained. If not, gasket will fall into fuel
tank).
(13) Using an approved gas holding tank, drain
fuel tank through fuel pump module opening.
Tank Removal
(1) After draining tank, temporarily place upper
section of fuel pump module back into fuel tank.
(2) Raise vehicle.
(3) If equipped, remove fuel tank skid plate and
tow hooks. Certain equipment packages will also
require removal of the trailer hitch. Refer to Tow
Hooks, Trailer Hitch or Skid Plate in 23, Body for
removal/installation procedures.
(4) Disconnect fuel filter ground strap.
(5) Disconnect fuel filter outlet line from body
retention clip located on frame near front/center of
tank (Fig. 41). Place a small screwdriver into side of
clip and twist for removal. Also disconnect Leak
Detection Pump (LDP) line (Fig. 41) from this clip.(6) Remove both 3/4º hoses at sides of Leak Detec-
tion Pump (LDP) (Fig. 41).
(7) Disconnect 3/4º flow management valve hose
(Fig. 41) at EVAP canister.
(8) Remove fuel fill hose clamp (Fig. 42) at fuel
tank, and disconnect hose from fuel tank.
(9) A third fuel line is attached to bottom of fuel
filter. The disconnection point (quick-connect fitting)
for this 3rd line is approximately 1 foot from front of
tank towards front of vehicle (Fig. 41). Clean connec-
tion point before disconnection. Disconnect by press-
ing on tabs at side of quick-connect fitting. Also
disconnect LDP vent line near this same point.
(10) Disconnect 2 vacuum/vent hoses from plastic
retention clip at left/front of fuel tank line (Fig. 41).
(11) Support tank with a hydraulic jack.
(12) Remove 4 fuel tank strap bolts (Fig. 41) (2 at
front of tank; 2 at rear of tank), and remove both
tank support straps (Fig. 41).
(13) Carefully lower tank a few inches and discon-
nect electrical connector at top of LDP (Fig. 43). To
disconnect electrical connector: Push upward on red
colored tab to unlock. Push on black colored tab
while removing connector.
Fig. 40 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)Fig. 41 FRONT OF FUEL TANK
1 - TANK MOUNTING BOLTS (4)
2 - TANK MOUNTING STRAPS (2)
3 - LEAK DETECTION PUMP (LDP)
4 - BODY RETENTION CLIP (CENTER)
5 - LDP HOSES
6 - HOSE TO FUEL MANAGEMENT VALVE
7 - BODY RETENTION CLIP (LEFT/FRONT)
8 - QUICK-CONECT FITTING
9 - LDP LINE
14 - 26 FUEL DELIVERYKJ
FUEL TANK (Continued)

(14) Continue lowering tank while guiding remain-
ing hoses and lines.
(15) If fuel tank is to be replaced, remove LDP,
fuel filter and fuel pump module from tank. Refer to
Leak Detection Pump, Fuel Filter and Fuel Pump
Module Removal/Installation procedures.
INSTALLATION
(1) If fuel tank is to be replaced, install LDP, fuel
filter and fuel pump module to tank. Refer to Leak
Detection Pump, Fuel Filter and Fuel Pump Module
Removal/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank while carefully guiding vent tubes/
hoses through frame rail and crossmember. Before
tank reaches body, connect electrical connector to
Leak Detection Pump (LDP).
(4) Continue raising tank until positioned to body.
(5) Attach two fuel tank mounting straps and 4
mounting bolts. Tighten bolts to 61 N´m (45 ft. lbs.)
torque.
(6) Connect 2 hoses to body retention clip at left/
front of tank.
(7) Connect fuel filter fuel line to main fuel line
(snaps together). After connecting, snap this line into
body retention clip. Also connect LDP vacuum hose
near this point.(8) Install fuel fill hose and hose clamp to fuel
tank fitting. Rotate hose until white painted index
mark on hose (Fig. 42) is located between alignment
notches on fuel tank fitting. Tighten clamp to 3.4
N´m (30 in. lbs.) torque.
(9) Connect fresh air and recirculation lines to fuel
fill tube.
(10) Connect 3/4º lines to Leak Detection Pump
(LDP).
(11) Connect 3/4º flow management valve hose to
EVAP canister.
(12) Snap remaining lines into body retention clip
at front/center of fuel tank.
(13) If equipped, install fuel tank skid plate,
trailer hitch and tow hooks. Refer to Tow Hooks,
Trailer Hitch or Skid Plate in 23, Body for removal/
installation procedures.
(14) Lower vehicle.
(15) Attach (snap on) 2 fuel filter fuel lines to top
of fuel pump module.
(16) Install electrical connector to top of fuel pump
module.
(17) Connect negative battery cable to battery.
(18) Fill fuel tank with fuel.
(19) Start engine and check for fuel leaks near top
of module.
(20) Apply silicone sealant to bottom of fuel pump
module metal access plate.
Fig. 42 FUEL FILL HOSE AT TANK
1 - FUEL FILL HOSE AT TANK
2 - HOSE CLAMP
3 - WHITE PAINTED INDEX MARK
4 - ALIGNMENT NOTCHES
5 - LEFT SIDE OF FUEL TANK
6 - FUEL FILL FITTINGFig. 43 LDP ELECTRICAL CONNECTOR
1 - LEAK DETECTION PUMP (LDP)
2 - ELECTRICAL CONNECTOR
3 - FUEL FILTER
KJFUEL DELIVERY 14 - 27
FUEL TANK (Continued)

The range of voltage output from the sensor is usually
between 4.6 volts at sea level to as low as 0.3 volts at
26 in. of Hg. Barometric pressure is the pressure
exerted by the atmosphere upon an object. At sea level
on a standard day, no storm, barometric pressure is
approximately 29.92 in Hg. For every 100 feet of alti-
tude, barometric pressure drops 0.10 in. Hg. If a storm
goes through, it can change barometric pressure from
what should be present for that altitude. You should
know what the average pressure and corresponding
barometric pressure is for your area.
REMOVAL
2.4L
The Manifold Absolute Pressure (MAP) sensor is
mounted into the rear of the intake manifold (Fig.
17). An o-ring is used to seal the sensor to the intake
manifold (Fig. 19).
(1) Disconnect electrical connector at sensor.
(2) Clean area around MAP sensor.
(3) Remove sensor mounting screw (TORX head).
(4) Remove MAP sensor from intake manifold.
(5) Check condition of sensor o-ring (Fig. 19).
3.7L
The Manifold Absolute Pressure (MAP) sensor is
mounted into the front of the intake manifold (Fig.
18). An o-ring is used to seal the sensor to the intake
manifold (Fig. 19).(1) Disconnect electrical connector at sensor.
(2) Clean area around MAP sensor.
(3) Remove 2 sensor mounting screws.
(4) Remove MAP sensor from intake manifold.
(5) Check condition of sensor o-ring (Fig. 19).
Fig. 17 MAP SENSOR LOCATION-2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
5 - ELECTRICAL CONNECTOR
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 18 MAP SENSOR / ECT SENSOR - 3.7L
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
Fig. 19 MAP SENSOR O-RING
1 - MAP SENSOR
2 - O-RING
KJFUEL INJECTION 14 - 39
MAP SENSOR (Continued)