Liberty, Wrangler 2006-2007

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Evacuate the A/C system.
  10.  
  11. Drain the power steering fluid, if equipped.
  12.  
  13. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Upper radiator hose
     
    Accessory drive belt and fan drive assembly
     
    Transmission cooler lines, if equipped
     
    Lower radiator hose
     
    Radiator and fan shroud
     
    Starter electrical connectors
     
    Alternator wiring connectors
     
    A/C compressor, if equipped
     
    Ignition coil wiring connector
     
    Oil pressure sender connector
     
    Wiring harness ground at the dipstick tube
     
    Heater hoses from the thermostat housing
     
    Water pump inlet tube
     
    Closed Crankcase Ventilation (CCV) hoses from the cylinder head and intake manifold
     
    Accelerator, transmission line pressure and speed control cables, if equipped
     
    Engine ground strap
     
    Power steering pressure switch, if equipped
     
    Engine Coolant Temperature (ECT) sensor
     
    Fuel injection wiring connectors
     
    Intake Air Temperature (IAT) sensor
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Vacuum hoses from the intake manifold
     
    Fuel line and bracket
     
    Power steering hoses from the steering gear, if equipped
     
    Oil filter
     
    Starter
     
    Engine support through bolts
     
    Exhaust front pipe
     
    Flywheel cover
     
    Torque converter, if equipped with automatic transmission
     
    Transmission flange bolts
     
    Left and right motor mounts
     
    Engine shock damper bracket
     

  14.  
  15. Place a support stand under the transmission.
  16.  
  17. Lift the engine out of the vehicle.
  18.  

To install:

  1. If equipped with a manual transmission, perform the following steps:
    1. Insert the transmission shaft into the clutch spline.
    2.  
    3. Align the flywheel housing to the engine.
    4.  
    5. Install the flywheel housing bolts. Torque the bolts to 28 ft. lbs. (38 Nm).
    6.  

  2.  
  3. If equipped with an automatic transmission, perform the following steps:
    1. Align the torque converter housing to the engine.
    2.  
    3. Torque the bolts to 28 ft. lbs. (38 Nm).

      Install the torque converter to flexplate bolts. Torque the bolts to 50 ft. lbs. (68 Nm).
       

    4.  

  4.  
  5. Install or connect the following:

    Engine onto the engine brackets. When properly aligned, torque the through bolts to 60 ft. lbs. (81 Nm).
     
    Inspection cover. Torque the bolts to 138 inch lbs. (16 Nm).
     
    Exhaust pipe. Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Starter motor. Tighten the bolts to 33 ft. lbs. (45 Nm).
     
    Oil filter
     
    Power steering hoses
     
    Fuel supply line to the fuel rail
     
    Fuel supply rail to the intake manifold
     
    Vacuum hoses to the intake manifold
     
    Power steering pressure switch electrical connector
     
    ECT sensor electrical connector
     
    Fuel injector connectors
     
    IAT sensor
     
    IAC motor
     
    TP sensor
     
    MAP sensor
     
    CKP sensor
     
    HO 2 S sensor connector
     
    Engine ground strap
     
    Heater hoses and water pump inlet tube
     
    Cruise control cable, if equipped
     
    Throttle cable
     
    Fan shroud and radiator. Torque the bolts to 75 inch lbs. (8 Nm).
     
    Transmission cooler lines, if equipped. Torque the bolts to 10 ft. lbs. (15 Nm).
     
    Fan drive assembly. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Drive belt
     
    Radiator hoses
     
    Ignition coil
     
    Distributor
     
    A/C compressor
     
    A/C high pressure switch
     
    Alternator
     
    Oil pressure sender
     
    Harness ground at the oil dipstick tube bracket
     
    A/C hoses
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the power steering system.
  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Recharge the A/C system.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  

2.4L Engine
  1. Disconnect the battery negative cable.
  2.  
  3. Remove hood. Mark hood hinge location for reinstallation.
  4.  
  5. Remove air cleaner assembly.
  6.  
  7. Remove radiator core support bracket.
  8.  
  9. Remove fan shroud with electric fan assembly.
  10.  
  11. Remove drive belt.
    NOTE
    It is not necessary to discharge the A/C system to remove the engine.

  12.  
  13. Remove A/C compressor and secure away from engine with lines attached.
  14.  
  15. Remove generator and secure away from engine.
    NOTE
    Do not remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.

  16.  
  17. Remove power steering pump with lines attached and secure away from engine.
  18.  
  19. Drain cooling system.
  20.  
  21. Remove coolant bottle.
  22.  
  23. Disconnect the heater hoses from the engine.
  24.  
  25. Disconnect heater hoses from heater core and remove hose assembly.
  26.  
  27. Disconnect throttle and speed control cables.
  28.  
  29. Remove upper radiator hose from engine.
  30.  
  31. Remove lower radiator hose from engine.
  32.  
  33. Disconnect the engine to body ground straps at the left side of cowl.
  34.  
  35. Disconnect the engine wiring harness at the following points:

    Click image to see an enlarged view

    Fig. Left side engine mount-2.4L engines



    Click image to see an enlarged view

    Fig. Right side engine mount-2.4L engines



    Click image to see an enlarged view

    Fig. Transmission mount-2.4L engines



    Intake air temperature (IAT) sensor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Idle Air Control (IAC) Motor
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold Absolute Pressure MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     
    Crankshaft Position Sensor
     

  36.  
  37. Remove coil over plugs.
  38.  
  39. Release fuel rail pressure.
  40.  
  41. Remove fuel rail and secure away from engine.
  42.  
  43. Remove the PCV hose.
  44.  
  45. Remove the breather hoses.
  46.  
  47. Remove the vacuum hose for the power brake booster.
  48.  
  49. Disconnect knock sensors.
  50.  
  51. Secure the left and right engine wiring harnesses away from engine.
  52.  
  53. Raise vehicle.
  54.  
  55. Disconnect oxygen sensor wiring.
  56.  
  57. Disconnect crankshaft position sensor.
  58.  
  59. Disconnect the engine block heater power cable, if equipped.
  60.  
  61. Disconnect the front driveshaft at the front differential and secure out of way.
  62.  
  63. Remove the starter.
  64.  
  65. Remove the ground straps from the engine
  66.  
  67. Disconnect the exhaust pipes at the manifold.
  68.  
  69. Remove the structural cover, if equipped.
  70.  
  71. Remove torque converter bolts, and mark location for reassembly.
  72.  
  73. Remove transmission bellhousing to engine bolts.
  74.  
  75. Loosen left and right engine mount thru bolts.
    NOTE
    It is not necessary to completely remove engine mount thru bolts, for engine removal.

  76.  
  77. Lower the vehicle.
  78.  
  79. Support the transmission with a suitable jack.
  80.  
  81. Connect a suitable engine hoist to the engine.
    WARNING
    The engine with a manual transmission, can be removed without removing the manual transmission. Use caution when attempting this procedure as the clearance is tight.

  82.  
  83. Remove engine from vehicle.
  84.  

To install:

  1. Position the engine in the vehicle.
  2.  
  3. Install both left and right side engine mounts into the frame mounts.
  4.  
  5. Raise the vehicle.
  6.  
  7. Install the transmission bellhousing to engine mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  8.  
  9. Tighten the engine mount thru bolts.
  10.  
  11. Install the torque converter bolts.
  12.  
  13. Connect the ground straps on the left and right side of the engine.
  14.  
  15. Install the starter.
  16.  
  17. Connect the crankshaft position sensor.
  18.  
  19. Install the engine block heater power cable, if equipped.
    WARNING
    The structural collar requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the collar.

  20.  
  21. Install the structural collar.
  22.  

Perform the following steps for installing structural collar.

  1. Step 1: Position collar between transmission and oil pan. Install collar to transmission bolts, hand start only.
  2.  
  3. Step 2: Install collar to oil pan bolts, hand snug only.
  4.  
  5. Step 3: Tighten collar to transmission bolts.
  6.  
  7. Step 4: Tighten collar to oil pan bolts.
  8.  

  1. Install the exhaust pipe.
  2.  
  3. Connect the oxygen sensors.
  4.  
  5. Lower vehicle.
  6.  
  7. Connect the knock sensors.
  8.  
  9. Connect the engine to body ground straps.
  10.  
  11. Install the power brake booster vacuum hose.
  12.  
  13. Install the breather hoses.
  14.  
  15. Install the PCV hose.
  16.  
  17. Install the fuel rail.
  18.  
  19. Install the coil over plugs.
  20.  
  21. Reconnect the engine wiring harness at the following points:

    Intake Air Temperature (IAT) sensor
     
    Fuel Injectors
     
    Throttle Position (TPS) Switch
     
    Idle Air Control (IAC) Motor
     
    Engine Oil Pressure Switch
     
    Engine Coolant Temperature (ECT) Sensor
     
    Manifold Absolute Pressure (MAP) Sensor
     
    Camshaft Position (CMP) Sensor
     
    Coil Over Plugs
     
    Crankshaft Position Sensor
     

  22.  
  23. Connect lower radiator hose.
  24.  
  25. Connect upper radiator hose.
  26.  
  27. Connect throttle and speed control cables.
  28.  
  29. Install the heater hose assembly.
  30.  
  31. Install coolant recovery bottle.
  32.  
  33. Install the power steering pump.
  34.  
  35. Install the generator.
  36.  
  37. Install the A/C compressor.
  38.  
  39. Install the drive belt.
  40.  
  41. Install the fan shroud with the electric fan assembly.
  42.  
  43. Install the radiator core support bracket.
  44.  
  45. Install the air cleaner assembly.
  46.  
  47. Refill the engine cooling system.
  48.  
  49. Install the hood.
  50.  
  51. Check and fill engine oil.
  52.  
  53. Connect the battery negative cable.
  54.  
  55. Start the engine and check for leaks.
  56.  

2.8L Diesel Engine
  1. Disconnect negative battery cable.
  2.  
  3. Drain cooling system.
  4.  
  5. Remove engine cover.
  6.  
  7. Remove engine cover mounting bracket retaining bolts and remove the bracket from the top of the engine.
  8.  
  9. Remove air cleaner assembly from the engine bay.
  10.  
  11. Recover refrigerant from A/C system.
  12.  
  13. Disconnect high side refrigerant line from the upper radiator support bracket.
  14.  
  15. Remove upper radiator support bracket retaining bolts and remove the support bracket.
  16.  
  17. Remove front grille and head lamp panel.
  18.  
  19. Remove high side refrigerant line retaining nut and remove the line from the condenser assembly. Position the line out of the way.
  20.  
  21. Remove low side refrigerant line retaining nut and remove line from the condenser assembly. Position the line out of the way.
  22.  
  23. Remove high side refrigerant line from A/C compressor and remove high side line.
  24.  
  25. Remove cooling fan and fan drive viscous clutch assembly .
  26.  
  27. Remove fan shroud retaining bolts and remove fan assembly and shroud together.
  28.  
  29. Disconnect charge air cooler outlet hose from charge air cooler .
  30.  
  31. Remove the charge air inlet hose from the charge air cooler .
  32.  
  33. Disconnect engine coolant hoses from engine assembly.
  34.  
  35. Disconnect coolant reservoir hoses and remove reservoir.
  36.  
  37. Remove power steering cooler retaining bolts and unclip air deflectors from both sides of the radiator (cooling module) assembly.
  38.  
  39. Remove cooling module assembly .
  40.  
  41. Remove accessory drive belt from the engine.
  42.  
  43. Accessing bolts through the pump pulley, remove power steering pump retaining bolts and position pump aside with lines still attached.
  44.  
  45. Disconnect heater core inlet and outlet hoses from the heater core .
  46.  
  47. Remove generator from engine. This will provide access to the wires beneath it.
  48.  
  49. Trace engine wiring and disconnect electrical connectors and tie straps one at a time until all wiring is disconnected from the engine assembly. When all the engine electrical harness is disconnected, separate the main engine wiring harness connectors at the right rear inner fender well then position the harness aside.
  50.  
  51. Raise and support the vehicle.
  52.  
  53. Remove the skid plate .
  54.  
  55. Disconnect the oil sending unit.
  56.  
  57. Remove starter motor from engine.
  58.  
  59. Remove chassis ground wire above starter mounting location on the engine block.
    NOTE
    For vehicles with manual transmission, remove the transmission.

  60.  
  61. Support the transmission with a jackstand.
  62.  
  63. Remove the flexplate access cover.
  64.  
  65. Remove the flexplate fasteners.
  66.  
  67. Remove transmission cross member fasteners.
  68.  
  69. Lower the transmission.
  70.  
  71. Remove the upper transmission to engine fasteners.
  72.  
  73. Raise the transmission.
  74.  
  75. Install the transmission cross member fasteners.
  76.  
  77. Remove the transmission jack.
  78.  
  79. Remove exhaust inlet pipe retaining bolts and disconnect exhaust pipe from turbocharger .
  80.  
  81. Remove transmission to engine retaining bolts.
  82.  
  83. Separate transmission cooler line(s) from retainer.
  84.  
  85. Remove both right and left side engine mount retaining nut.
  86.  
  87. Lower vehicle.
  88.  
  89. Remove left side engine mount retaining nut.
  90.  
  91. Remove exhaust manifold rear heat shield.
  92.  
  93. Disconnect the fuel supply and return lines.
  94.  
  95. Remove crankshaft sensor heat shield.
  96.  
  97. Disconnect crankshaft position sensor, located on the right rear of the engine .
  98.  
  99. Remove the oil separator from the cylinder head cover/intake manifold .
  100.  
  101. Connect a suitable lifting device to engine assembly.
  102.  
  103. Place a floor jack under the transmission to support the transmission.
  104.  
  105. With engine and transmission supported by a lifting device separate the engine from the transmission.
  106.  
  107. Lift the engine assembly out of the engine bay.
  108.  

To install:

  1. Install engine assembly and align with the transmission .
    NOTE
    For vehicle equipped with a manual transmission, Install the transmission.

  2.  
  3. Remove engine lifting devise.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Install accessible engine to transmission housing bolts. Tighten bolts to 50 ft. lbs. (68 Nm).
  8.  
  9. Install the engine mount fasteners.
  10.  
  11. Support the transmission and remove the rear transmission crossmember .
  12.  
  13. Lower the transmission and install the upper transmission to engine fasteners. Tighten bolts to 50 ft. lbs. (68 Nm).
  14.  
  15. Raise the transmission and install the transmission crossmember.
  16.  
  17. Install the flexplate to torque converter fasteners and install the shield.
  18.  
  19. Install the engine ground wire above the starter.
  20.  
  21. Install the starter.
  22.  
  23. Connect the transmission cooler lines to the oil pan retainers.
  24.  
  25. Connect the exhaust .
  26.  
  27. Lower the vehicle.
  28.  
  29. Install the oil separator .
  30.  
  31. Connect the crankshaft sensor and install the heat shield .
  32.  
  33. Connect the heater hose inlet and out let hoses .
  34.  
  35. Install the power steering pump.
  36.  
  37. Install the generator.
  38.  
  39. Connect the fuel lines.
  40.  
  41. Position and connect the main engine wiring harness.
  42.  
  43. Install the accessory drive belt.
  44.  
  45. Install the cooling module .
  46.  
  47. Connect the power steering cooler and fasten the air deflectors.
  48.  
  49. Install the coolant reservoir .
  50.  
  51. Connect the engine coolant hoses.
  52.  
  53. Connect the charge air inlet hose .
  54.  
  55. Connect the charge air outlet hose .
  56.  
  57. Install the cooling fan assembly and shroud.
  58.  
  59. Install high side refrigerant line.
  60.  
  61. Install the low side refrigerant line.
  62.  
  63. Install the front grille and head lamp panel.
  64.  
  65. Install the upper radiator support bracket.
  66.  
  67. Install the air cleaner assembly.
  68.  
  69. Install the engine cover bracket and engine cover.
  70.  
  71. Evacuate and recharge A/C.
  72.  
  73. Fill cooling system.
  74.  
  75. Fill crankcase with the correct viscosity oil, to the proper level.
  76.  
  77. Start engine, allow to warm, turn engine off and inspect for leaks.
  78.  

3.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Air cleaner assembly
     
    Radiator
     
    Electric and mechanical fan assemblies
     
    A/C compressor, if equipped, and secure it out of the way with the lines attached. DO NOT DISCHARGE!
     
    Power steering pump, with the lines attached
     
    Alternator
     
    Coolant bottle
     
    Heater hoses
     
    Accelerator and speed control cables
     
    Lower and upper radiator hoses
     
    Engine ground straps
     
    Intake Air Temperature (IAT) sensor
     
    Fuel injection wiring connectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Oil pressure sender connector
     
    Engine Coolant Temperature (ECT) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft position sensor
     
    Ignition coil wiring connector
     
    Crankshaft Position (CKP) sensor
     
    Coil pack
     
    Fuel rail
     
    PCV hose
     
    Vacuum hoses from the intake manifold
     
    Knock sensor connectors
     
    Oil dipstick tube
     
    Intake manifold
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Block heater connector
     
    Front driveshaft at the differential
     
    Starter
     
    Structural cover
     
    With a manual transmission, remove the transmission
     
    Torque converter bolts and matchmark the converter
     
    Automatic transmission-to-engine bolts
     
    Exhaust front pipes
     
    Left and right engine mounts
     

  10.  
  11. Place a support stand under the transmission.
  12.  
  13. Install an engine lift plate
  14.  
  15. Lift the engine out of the vehicle.
  16.  

To install:

  1. If equipped with a manual transmission, install the transmission
  2.  
  3. Lower the engine and install the mounts. Don-t tighten the bolts yet.
  4.  
  5. If equipped with an automatic transmission, perform the following steps:
    1. Align the torque converter housing to the engine.
    2.  
    3. Torque the bolts to 30 ft. lbs. (41 Nm).

      Install the torque converter to flexplate bolts. Torque the bolts to 50 ft. lbs. (68 Nm).
       

    4.  

  6.  
  7. Install or connect the following:
    WARNING
    The structural cover must be held tightly against the engine and bellhousing during tightening. The torque for all bolts is 40 ft. lbs. (54 Nm); the bolts must be tightened in the order shown.



    Torque the through bolts to 45 ft. lbs. (61 Nm).
     
    Engine ground strap
     
    Starter motor
     
    CKP sensor
     
    Block heater cable
     
    Structural cover.
     



    Click image to see an enlarged view

    Fig. Tighten the structural cover bolts in this order-3.7L engine



    Exhaust pipes. New flange clamps MUST be used!
     
    HO 2 S sensor connectors
     
    KS sensors
     
    Intake Manifold
     
    Dipstick tube
     
    Vacuum hoses to the intake manifold
     
    PCV and breather hoses
     
    Fuel rail
     
    Ignition coil
     
    IAT sensor
     
    Fuel injector connectors
     
    TP sensor
     
    IAC motor
     
    Oil pressure sender
     
    ECT sensor electrical connector
     
    MAP sensor
     
    CMP sensor
     
    Radiator hoses
     
    Cruise control cable, if equipped
     
    Throttle cable
     
    Heater hoses
     
    Coolant bottle
     
    Power steering pump
     
    Alternator
     
    A/C compressor
     
    Radiator
     
    Fan assemblies
     
    Air cleaner assembly
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the power steering system.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

 
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