Description: Removal & Installation Jeep Liberty II

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 the Counterbalance Shaft Remover/Installer 8641 (1), carefully install counterbalance shaft into engine . 1 - IDLER SHAFT 2 - COUNTERBALANCE SHAFT THRUST PLATE 3 - COUNTERBALANCE SHAFT DRIVE GEAR 4 - RETAINING BOLT
3. Install Counterbalance shaft thrust plate retaining bolt (4) 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. Tighten the thrust plate retaining bolt (4) to 28 N.m (250 in. lbs.)
6. Remove the chain guide bolt so that guide can be installed.

Scheme 88

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

Scheme 89

Scheme 90

Scheme 91

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge (1) check the ring end gap. Replace any rings not within specification. 1 - FEELER GAUGE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
5. Measure the ring side clearance as shown in illustration make sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART Ring Position Groove Clearance Maximum Clearance Upper Ring 0.051 - 0.094 mm 0.11 mm - (0.0020 - 0.0037 in.) (0.004 in.) Intermediate Ring 0.04 - 0.08 mm 0.10 mm - (0.0016 - 0.0031 in.) (0.004 in.) Oil Control Ring 0.019 - 0.229 mm 0.25 mm (Steel Rails) (0.0007-.0090 in.) (0.010 in.) Ring Position Ring Gap Wear Limit Upper Ring 0.20 - 0.36 mm 0.43 mm - (0.0079 - 0.0142 in.) (0.0017 in.) Intermediate Ring 0.37 - 0.63 mm 0.74 mm - (0.0146 - 0.0249 in.) (0.029 in.) Oil Control Ring 0.025 - 0.76 mm 1.55 mm (Steel Rail) (0.0099 - 0.03 in.) (0.061 in.)
7. The No. 1 and No. 2 piston rings have a different cross service information. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: Oil ring expander. Upper oil ring side rail. Lower oil ring side rail. No. 2 Intermediate piston ring. No. 1 Upper piston ring.
8. Install the oil ring expander.
9. Install upper side rail (1) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.
10. Install No. 2 intermediate piston ring using a piston ring installer.
11. Install No. 1 upper piston ring using a piston ring installer. 1 - SIDE RAIL UPPER 2 - NO. 1 RING GAP 3 - PISTON PIN 4 - SIDE RAIL LOWER 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
12. Position piston ring end gaps as shown in illustration. It is important that expander ring gap (5) is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.

Scheme 92

The pistons (2) are made of a high strength aluminum alloy. The connecting rods (1) are made of forged powdered metal, with a "fractured cap" design. A full floating piston pin is used to attach the piston to the connecting rod.

Scheme 93

Inspect the connecting rod bearings for scoring. Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting. Replace any bearing that shows abnormal wear.

Inspect the connecting rod journals for signs of scoring, nicks and burrs.

Misaligned or bent connecting rods can cause abnormal wear on pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft connecting rod journals. If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod, inspect it for correct rod alignment. Replace misaligned, bent or twisted connecting rods.

Scheme 94

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Scheme 97

1. Wipe the oil from the connecting rod journal.
2. Lubricate the upper bearing insert and position in connecting rod. Center bearing insert (2) in connecting rod (1)
3. Use piston ring compressor (3) and Connecting Rod Guides 8507 to install the rod and piston assemblies. The oil slinger slots in the rods must face front of the engine. The "F"'s near the piston wrist pin bore (1) should point to the front of the engine.
4. Install the lower bearing insert in the bearing cap. Center bearing insert in connecting rod. . The lower insert must be dry. Place strip of Plastigage across full width of the lower insert at the center of bearing cap. Plastigage must not crumble in use. If brittle, obtain fresh stock.
5. Install bearing cap and connecting rod on the journal and tighten bolts to 27 N.m (20 ft. lbs.) plus a 90° turn. DO NOT rotate crankshaft. Plastigage will smear, resulting in inaccurate indication.
6. Remove the bearing cap and determine amount of bearing-to-journal clearance by measuring the width of compressed Plastigage (2). Refer to «3.7L ENGINE»(ref-350033-S03841953552009121400000) Specifications for the proper clearance. Plastigage should indicate the same clearance across the entire width of the insert. If the clearance varies, it may be caused by either a tapered journal, bent connecting rod or foreign material trapped between the insert and cap or rod.
7. If the correct clearance is indicated, replacement of the bearing inserts is not necessary. Remove the Plastigage from crankshaft journal and bearing insert. Proceed with installation. Bearing Mark SIZE USED WITH JOURNAL SIZE 0.025 OS 0.025 mm 0.001 in. 57.883 - 57.867 mm 2.2788 - 2.2783 in. STD STANDARD STANDARD 57.908 - 57.892 mm 2.2798 - 2.2792 in. 0.250 US 0.250 mm 0.010 in. 57.658 - 57.646 mm 2.2700 - 2.2695 in.
8. If bearing-to-journal clearance exceeds the specification, determine which services bearing set to use the bearing sizes are as follows: CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
9. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.
10. Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N.m (20 ft. lbs.) plus a 90° turn.

Slide snug-fitting feeler gauge between the connecting rod and crankshaft journal flange. Refer to 3.7L ENGINE Specifications for the proper clearance. Replace the connecting rod if the side clearance is not within specification.

Scheme 98

Scheme 99

1. To correctly select the proper size piston, a cylinder bore gauge (2), capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
2. Measure the inside diameter of the cylinder bore (3) at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B. 1 - MOLY COATED 2 - MOLY COATED
3. The coated pistons (1,2) will be serviced with the piston pin and connecting rod pre-assembled.
4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston (1,2) will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY . To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

REMOVAL

1. Disconnect negative cable from battery.
2. Remove the following components: Oil pan and gasket/windage tray. See «Engine/Lubrication/PAN, Oil - Removal»(ref-350033-S06027367112009121400000) . Cylinder head covers. See «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-350033-S30312565002009121400000) and «Engine/Cylinder Head/COVER(S), Cylinder Head - Removal»(ref-350033-S21428737172009121400000) . Timing chain cover. See «Engine/Valve Timing/COVER(S), Engine Timing - Removal»(ref-350033-S09176476182009121400000) . Cylinder head(s). See «Engine/Cylinder Head - Removal»(ref-350033-S39188103872009121400000) and «Engine/Cylinder Head - Removal»(ref-350033-S39188103872009121400000) .
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
5. Remove connecting rod cap. Install the Connecting Rod Guides 8507 into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.

Scheme 100

1. Disconnect negative cable from battery.
2. Remove accessory drive belt. Refer to «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-350049-S42585242162009121400000) .
3. Remove A/C compressor mounting fasteners and set aside.
4. Drain cooling system. Refer to «Cooling - Standard Procedure»(ref-350049-S21995734202009121400000) .
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 «Cooling/Engine/FAN, Cooling - Removal»(ref-350049-S33089968402009121400000) .
9. Remove crankshaft damper bolt.
10. Remove damper using the Crankshaft Insert 8513A (1) and the Three Jaw Puller 1026 (2) . 1 - SPECIAL TOOL 8511
11. Using Seal Remover 8511, remove crankshaft front seal (1) .

Scheme 101

1. Using the Seal Installer 8348 (2) and Damper Installer 8512A (3), install crankshaft front seal .
2. Install vibration damper. See «Engine/Engine Block/DAMPER, Vibration - Installation»(ref-350033-S32125941492009121400000) .
3. Install radiator cooling fan and shroud. Refer to «Cooling/Engine/FAN, Cooling - Installation»(ref-350049-S04831714512009121400000) .
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 «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-350049-S32613456632009121400000) .
7. Refill cooling system. Refer to «Cooling - Standard Procedure»(ref-350049-S21995734202009121400000) .
8. Connect negative cable to battery.