CRANK SHAFT JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
OPERATION............................1
WARNING.............................2
DIAGNOSIS AND TESTING - CLUTCH........2
SPECIFICATIONS - CLUTCH...............5
CLUTCH DISC
REMOVAL.............................6
INSTALLATION..........................6
CLUTCH RELEASE BEARING
REMOVAL.............................6
INSTALLATION..........................6
FLYWHEEL
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - FLYWHEEL......8
PILOT BEARING
REMOVAL.............................8
INSTALLATION..........................8LINKAGE
REMOVAL.............................8
INSTALLATION..........................9
MASTER CYLINDER
INSPECTION...........................9
CLUTCH PEDAL
REMOVAL.............................10
INSTALLATION.........................10
CLUTCH SWITCH OVERRIDE RELAY
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................10
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH....................11
CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, dry-
type disc, diaphragm style pressure plate and
hydraulic linkage. The flywheel is bolted to the rear
flange of the crankshaft. The clutch pressure plate is
bolted to the flywheel with the clutch disc between
these two components. The clutch system provides
the mechanical, link between the engine and the
transmission. The system is designed to transfer the
torque output of the engine, to the transmission
while isolating the transmission from the engine fir-
ing pulses to minimize concerns such as gear rattle.
OPERATION
The clutch operates with leverage, clamping force
and friction. The disc serves as the friction element,
the diaphragm spring and pressure plate provide the
clamping force. The clutch pedal, hydraulic linkage,
release lever and bearing provide the leverage.
The clutch master cylinder push rod is connected
to the clutch pedal. When the clutch pedal is
depressed, the slave cylinder is operated by the
clutch master cylinder mounted on the dash panel.
The release fork is actuated by the hydraulic slave
cylinder mounted on the transmission housing. The
release bearing is operated by a release fork pivoting
on a ball stud mounted in the transmission housing.
The release bearing then depresses the pressure
plate spring fingers, thereby releasing pressure on
the clutch disc and allowing the engine crankshaft to
spin independently of the transmission input shaft.
KJCLUTCH 6 - 1

WARNING
WARNING:: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
DIAGNOSIS AND TESTING - CLUTCH
Drive the vehicle at normal speeds. Shift the trans-
mission through all gear ranges and observe clutch
action. If the clutch chatters, grabs, slips or does not
release properly, remove and inspect the clutch com-
ponents. If the problem is noise or hard shifting, fur-
ther diagnosis may be needed as the transmission or
another driveline component may be at fault.
NOTE: Vehicles equipped with a Dual Mass Fly-
wheel may produce a rattle when the engine is shut
off. This noise is considered normal.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, water or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter,
slip and grab. Inspect components for oil, hydraulic
fluid or water/road splash contamination.
Oil contamination indicates a leak at either the
rear main seal or transmission input shaft. Clutch
fluid leaks are usually from damaged slave cylinder
push rod seals. Heat buildup caused by slippage
between the pressure plate, disc and flywheel can
bake the oil residue onto the components. The glaze-
like residue ranges in color from amber to black.Road splash contamination is dirt/water entering
the clutch housing due to loose bolts, housing cracks.
Driving through deep water puddles can force water/
road splash into the housing through such openings.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems are caused
by wear or damage clutch components. A visual
inspection of the release components will usually
reveal the problem part.
Release problems can result in hard shifting and
noise. Look for leaks at the clutch cylinders and
interconnecting line and loose slave cylinder bolts.
Also worn/loose release fork, pivot stud, clutch disc,
pressure plate or release bearing.
Engagement problems can result in slip, chatter/
shudder and noisy operation. The causes may be
clutch disc contamination, wear, distortion or fly-
wheel damage. Visually inspect to determine the
actual cause of the problem.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
PRESSURE PLATE AND DISC RUNOUT
Check the clutch disc before installation. Axial
(face) runout of anewdisc should not exceed 0.50
mm (0.020 in.). Measure runout about 6 mm (1/4 in.)
from the outer edge of the disc facing. Obtain
another disc if runout is excessive.
Check condition of the clutch before installation. A
warped cover or diaphragm spring will cause grab
and incomplete release or engagement. Be careful
when handling the cover and disc. Impact can distort
the cover, diaphragm spring, release fingers and the
hub of the clutch disc.
Use an alignment tool when positioning the disc on
the flywheel. The tool prevents accidental misalign-
ment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing.
FLYWHEEL RUNOUT
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
6 - 2 CLUTCHKJ
CLUTCH (Continued)

Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can alsoweaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
DIAGNOSIS CHART
The diagnosis charts Diagnosis Chart describe
common clutch problems, causes and correction. Con-
ditions, causes and corrective action are outlined in
the indicated columns.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.1. Leak at rear main engine seal or
transmission input shaft seal.1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.1. Release bearing sticking or
binding and does not return to the
normal running position.1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.1. Rough handling. Impact bent
cover, spring, or disc.1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.2. Tighten clutch cover using proper
procedure.
KJCLUTCH 6 - 3
CLUTCH (Continued)

CLUTCH DISC
REMOVAL
(1) Remove transmission.
(2) Mark position of pressure plate on flywheel
with paint or a scriber for assembly reference, if
clutch is not being replaced.
(3) Loosen pressure plate bolts evenly and in rota-
tion to relieve spring tension and avoid warping the
plate.
(4) Remove pressure plate bolts and pressure plate
and disc.
INSTALLATION
(1) Lightly scuff sand flywheel face with 180 grit
emery cloth, then clean with a wax and grease
remover.
(2) Lubricate pilot bearing with Mopar high tem-
perature bearing grease or equivalent.
(3) Check runout and operation ofnewclutch disc.
NOTE: Disc must slide freely on transmission input
shaft splines.
(4) With the disc on the input shaft, check face
runout with dial indicator. Check runout at disc hub
6 mm (1/4 in.) from outer edge of facing. Obtain
another clutch disc if runout exceed 0.5 mm (0.020
in.).
(5) Position clutch disc on flywheel with side
marked flywheel against the flywheel.
NOTE: If not marked, the flat side of disc hub goes
towards the flywheel on the 3.7L engine and
towards the transmission on 2.4L engine.
(6) Insert clutch alignment tool through the clutch
disc and into the pilot bearing (Fig. 1).
(7) Position clutch pressure plate over disc and on
the flywheel (Fig. 1).
(8) Install pressure plate bolts finger tight.
CAUTION: Use only the factory bolts to mount the
pressure plate. The bolts must be the correct size.
If bolts are too short, there isn't enough thread
engagement, if too long bolts interfere with the Dual
Mass Flywheel.
(9) Tighten pressure plate bolts evenly and in rota-
tion a few threads at a time.
CAUTION: The bolts must be tightened evenly and
to specified torque to avoid distorting the pressure
plate.(10) Tighten pressure plate bolts to 31 N´m (23 ft.
lbs.) on 2.4L engines and 50 N´m (37ft. lbs.) on 3.7L
engines.
(11) Apply light coat of Mopar high temperature
bearing grease or equivalent to clutch disc hub and
splines of transmission input shaft.
CAUTION: Do not over lubricate shaft splines. This
will result in grease contamination of disc.
(12) Install transmission.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission.
(2) Disconnect release bearing from release lever
and remove the bearing (Fig. 2).
(3) Inspect bearing slide surface of transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(4) Inspect release fork and fork pivot. Be sure
pivot is secure and in good condition. Be sure fork is
not distorted or worn. Replace release fork retainer
spring if bent or damaged.
INSTALLATION
(1) Lubricate crankshaft pilot bearing with Mopar
high temperature bearing grease or equivalent. Apply
grease to end of long shank, small diameter flat
blade screwdriver. Then insert tool through clutch
disc hub to reach bearing.
Fig. 1 ALIGNING CLUTCH DISC
1 - FLYWHEEL
2 - PRESSURE PLATE
3 - CLUTCH DISC ALIGNMENT TOOL
6 - 6 CLUTCHKJ

(2) Lubricate input shaft splines, bearing retainer
slide surface, fork pivot and release fork pivot sur-
face.
(3) Install new release bearing. Be sure bearing is
properly secured to release fork.
(4) Install transmission.
FLYWHEEL
DESCRIPTION
STANDARD FLYWHEEL
The standard flywheel is used on the 3.7L engine.
The flywheel (Fig. 3) is a heavy plate bolted to the
rear of the crankshaft. The flywheel incorporates the
ring gear around the outer circumference to mesh
with the starter to permit engine cranking. The rear
face of the flywheel serves as the driving member to
the clutch disc.
DUAL MASS FLYWHEEL
The Dual Mass Flywheel is used on the 2.4 l
engine (Fig. 4). The flywheel incorporates the ring
gear around the outer circumference to mesh with
the starter to permit engine cranking. The primary
flywheel side is bolted to the crankshaft. The second-
ary flywheel face serves as the driving member to the
clutch disc. Internal springs between the flywheels
are use to dampen energy.
OPERATION
The flywheel serves to dampen the engine firing
pulses. The heavy weight of the flywheel relative to
the rotating mass of the engine components serves to
stabilize the flow of power to the remainder of the
drivetrain. The crankshaft has the tendency toattempt to speed up and slow down in response to
the cylinder firing pulses. The flywheel dampens
these impulses by absorbing energy when the crank-
shaft speeds and releasing the energy back into the
system when the crankshaft slows down.
Fig. 2 CLUTCH RELEASE BEARING
1 - RELEASE BEARING
2 - RELEASE FORK
Fig. 3 FLYWHEEL
1 - CRANKSHAFT
2 - RING GEAR
3 - FLYWHEEL
Fig. 4 DUAL MASS FLYWHEEL
1 - LOCATING STUD
2 - BEARING
3 - SECONDARY FLYWHEEL
4 - DAMPER SPRING
5 - RING GEAR
6 - PRIMARY FLYWHEEL
7 - FRICTION DISC
KJCLUTCH 6 - 7
CLUTCH RELEASE BEARING (Continued)

On a Dual Mass Flywheel the additional secondary
mass coupled to the transmission lowers the natural
frequency of the transmission rotating elements. This
decreases the transmission gear rattle. The damper
springs between the two flywheel masses replace the
clutch disc damper springs and assist in a smooth
transfer of torque to the transmission.
CAUTION: The Dual Mass Flywheel is serviced as
an assembly only and should never be taken apart.
DIAGNOSIS AND TESTING - FLYWHEEL
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can also
weaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
PILOT BEARING
REMOVAL
(1) Remove the transmission.
(2) Remove pressure plate and clutch disc.
(3) Remove pilot bearing with an internal (blind
hole) puller.
INSTALLATION
(1) Lubricate new bearing with Mopar high tem-
perature bearing grease or equivalent.
(2) Start new bearing into crankshaft by hand.
Then seat bearing with clutch alignment tool (Fig. 5).
(3) Lightly scuff sand flywheel surface with 180
grit emery cloth. Then clean surface with wax and
grease remover.
(4) Install clutch disc and pressure plate.
(5) Install the transmission.
LINKAGE
REMOVAL
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Raise vehicle.
(2) Remove fasteners attaching slave cylinder to
clutch housing.
(3) Remove slave cylinder from clutch housing
(Fig. 6).
(4) Disengage clutch fluid line from body clips, if
applicable.
(5) Lower vehicle.
(6) Verify cap on clutch master cylinder reservoir
is tight to avoid spilling fluid during removal.
(7) Remove clutch master cylinder attaching nuts
(Fig. 7).
(8) Disengage captured bushing on clutch master
cylinder actuator from pivot pin on pedal arm.
Fig. 5 Pilot Bearing Installer
1 - PILOT BEARING
2 - ALIGNMENT TOOL
6 - 8 CLUTCHKJ
FLYWHEEL (Continued)

CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts its stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 3).INSTALLATION - 3.7L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 3).
(2) Install new belt (Fig. 3). Route the belt around
all pulleys except the idler pulley. Rotate the ten-
sioner arm until it contacts its stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator (Fig. 4). On 3.7L Engines the gap
between the tang and the housing stop ( measure-
ment A ) must not exceed 24 mm (.94 inches).
Fig. 3 Belt Routing - 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 4 Accessory Drive Belt Wear Indicator
1 - AUTOMATIC TENSIONER ASSEMBLY
7 - 18 ACCESSORY DRIVEKJ
DRIVE BELTS - 3.7L (Continued)

CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under belt tension.
(8) Remove four bolts securing fan blade assembly
to viscous fan drive.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
INSTALLATION
(1) Assemble fan blade to viscous fan drive.
Tighten mounting bolts to 27 N´m (20 ft. lbs.) torque.
NOTE: The vicous fan and fan shroud must be
installed as an assembly.
(2) Gently lay vicous fan into fan shroud.
(3) Install the fan shroud to radiator mounting
bolts, torque bolts to (5.5N´M or 50 in´lbs).
(4) Thread the fan and fan drive onto the water
pump pulley, and tighten nut using special tool 6958
spanner wrench and 8346 adapters.
(5) Connect the electrical connector for the electric
fan.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
for correct belt routing.
WATER PUMP
DESCRIPTION
DESCRIPTION - WATER PUMP
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core.
The pump is driven from the engine crankshaft by a
single serpentine drive belt.
The water pump impeller is pressed onto the rear
of a shaft that rotates in bearings pressed into the
housing. The housing has two small holes to allow
seepage to escape. The water pump seals are lubri-
cated by the antifreeze in the coolant mixture. No
additional lubrication is necessary.
Both heater hoses are connected to fittings on the
timing chain front cover. The water pump is also
mounted directly to the timing chain cover and is
equipped with a non serviceable integral pulley (Fig.
17).
DESCRIPTION
The 3.7L engine uses an internal water/coolant
bypass system. The design uses galleries in the tim-
ing chain cover to circulate coolant during engine
warm-up preventing the coolant from flowing
Fig. 17 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
2 - TIMING CHAIN COVER
3 - THERMOSTAT HOUSING
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
KJENGINE 7 - 29
RADIATOR - FAN - VISCOUS (Continued)

through the radiator. The thermostat uses a stub
shaft located at the rear of the thermostat to control
flow through the bypass gallery.
OPERATION - WATER PUMP
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
REMOVAL
The water pump on 3.7L engines is bolted directly
to the engine timing chain case cover.
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan/viscous fan drive assembly from
water pump (Fig. 18) (Refer to 7 - COOLING/EN-
GINE/FAN DRIVE VISCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(4) If water pump is being replaced, do not unbolt
fan blade assembly from thermal viscous fan drive.
(5) Remove two fan shroud-to-radiator screws, Dis-
connect the coolant overflow hose.
(6) Remove upper fan shroud and fan blade/viscous
fan drive assembly from vehicle.
(7) After removing fan blade/viscous fan drive
assembly,do notplace thermal viscous fan drive in
horizontal position. If stored horizontally, silicone
fluid in viscous fan drive could drain into its bearing
assembly and contaminate lubricant.
(8) Remove accessory drive belt (Fig. 19) (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) Remove lower radiator hose clamp and remove
lower hose at water pump.
(10) Remove seven water pump mounting bolts
and one stud bolt.
Fig. 18 Viscous Fan and Fan Drive 3.7L
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
Fig. 19 Automatic Belt TensionerÐ3.7L
1 - AUTOMATIC TENSIONER
2 - WATER PUMP PULLEY
7 - 30 ENGINEKJ
WATER PUMP (Continued)

CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(11) Remove water pump and gasket. Discard gas-
ket.
CLEANING
Clean the gasket mating surface. Use caution not
to damage the gasket sealing surface.
INSPECTION
Inspect the water pump assembly for cracks in the
housing, Water leaks from shaft seal, Loose or rough
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.
INSTALLATION
The water pump on 3.7L engines is bolted directly
to the engine timing chain case cover.
(1) Clean gasket mating surfaces.
(2) Using a new gasket, position water pump and
install mounting bolts as shown. (Fig. 20). Tighten
water pump mounting bolts to 54 N´m (40 ft. lbs.)
torque.
(3) Spin water pump to be sure that pump impel-
ler does not rub against timing chain case/cover.
(4) Connect radiator lower hose to water pump.
(5) Relax tension from belt tensioner. Install drive
belt (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).CAUTION: When installing the serpentine accessory
drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 21) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
(6) Position upper fan shroud and fan blade/vis-
cous fan drive assembly.
(7) Be sure the upper and lower portions of the fan
shroud are firmly connected. All air must flow
through the radiator.
(8) Install two fan shroud-to-radiator screws.
(9) Be sure of at least 25 mm (1.0 inches) between
tips of fan blades and fan shroud.
(10) Install fan blade/viscous fan drive assembly to
water pump shaft (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(11) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Connect negative battery cable.
(13) Start and warm the engine. Check for leaks.
Fig. 20 Water Pump InstallationÐ3.7L
1 - WATER PUMP
2 - TIMING CHAIN COVER
Fig. 21 Belt Routing 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
KJENGINE 7 - 31
WATER PUMP (Continued)