How do I remove the valve cover on 2002 jeep liberty 2.4l 4 cyclinder engine. The intake manifold is blocking bolts and cannot see the best way to remove it.

47steps in the factory FSM book covers that. answer yes.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the engine oil.
3. Drain the cooling system.
4. Properly relieve the fuel system pressure.
5. Remove the hood.
6. Remove the engine appearance cover.
7. Remove the air intake assembly.
8. Disconnect both cables from the battery.
9. Remove the battery and battery tray.
10. Remove the coolant reservoir.
11. Remove the power steering reservoir.
12. Remove the windshield washer reservoir.
13. Remove the coolant hoses from coolant adapter.
14. Remove the grill closure panel.
15. Remove the upper radiator hose support.
16. Disconnect the engine electrical connectors and reposition harness.
17. Remove the air intake tube from throttle body.
18. Disconnect the fuel line from fuel rail.
19. Remove the vacuum lines from throttle body and intake manifold.
20. Remove the wiring harness from the intake.
21. Remove the throttle body support bracket.
22. Disconnect the electronic throttle control and manifold flow control valve electrical connectors.
23. Remove the PCV hose, and make-up air hose from valve cover.
24. Remove the dipstick.
25. Remove the intake manifold mounting bolts and remove the intake manifold. Refer to Intake Manifold, removal & installation.
26. Disconnect the electrical connectors and reposition the harness.
27. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
28. Remove the power steering line support at the engine mount and exhaust manifold.
29. Remove the power steering pump and set it aside.
30. Remove the upper idler pulley.
31. Remove the ground strap near the right tower.
32. Raise and safely support the vehicle.
33. Remove the right front wheel.
34. Remove the engine splash shield.
35. Remove the torque converter inspection cover and match-mark the torque converter to the flywheel.
36. Remove the torque converter bolts.
37. Remove the lower bell housing mounting bolts.
38. Remove the A/C compressor mounting bolts.
39. Remove the alternator and the lower idler pulley.
40. Disconnect the Crankshaft Position (CKP) sensor electrical connector and remove the sensor.
41. Remove the exhaust variable valve timing solenoid.
42. Install an engine lift chain to cylinder head, as shown.
43. Connect the chain to the rear engine lift hook.
44. Install engine lifting crane.
45. Remove the right engine mount through-bolt.
46. Remove the engine mount adapter retaining bolts and the mount adapter.
47. Carefully lift the engine from the engine compartment.,,,end. removal.

• ENGINE 2.4L

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Balance Shaft Carrier to Block-Bolts

54

40

-

Balance Shaft Gear Cover-Double Ended Fastener

12

-

105

Balance Shaft Sprocket- Bolt

28

-

250

Balance Shaft Chain Tensioner-Bolts

12

-

105

Balance Shaft Carrier Cover-Bolts

12

-

105

Camshaft Sprocket-Bolt

101

75

-

Connecting Rod Cap-Bolts

54 +1/4 turn

40 +1/4 turn

-

Crankshaft Main Bearing Cap/Bedplate - M8 Bolts

34

250

-

M11 Bolts

41 +1/4 Turn

30 +1/4 Turn

-

Crankshaft Damper

136

100

-

Cylinder Head Cover- Bolts

12

-

105

Flex Plate to Crankshaft

95

70

-

Flywheel Mounting Bolts

81

60

-

Engine Mount Bracket Right-Bolts

61

45

-

Exhaust Manifold to Cylinder Head-Bolts

23

-

200

Exhaust Manifold Heat Shield-Bolts

12

-

105

Intake Manifold - Lower -Bolts

28

-

250

Oil Filter

20

15

-

Oil Pan-Bolts

12

-

105

Oil Pan Drain-Plug

27

20

-

Oil Pump to Block-Bolts

28

-

250

Oil Pump Cover Plate-Bolts

12

-

105

Oil Pump Pick-up Tube-Bolt

28

20

-

Oil Pump Relief Valve-Cap

41

30

-

Spark Plugs

28

Timing Belt Covers - Front Covers to Rear Cover-Bolts

12

-

105

- Rear Cover-Bolts

12

-

105

Timing Belt Tensioner Assembly-Bolts

61

45

-

I have an 2003 Jeep liberty and removed the oil pan the shortcut method. First of all, take a look at the oil pan lip. Its really 3 layers. You want to seperate the bottom layer which is the actual oil pan. The second layer is an oil pan insert which is bolted to the oil pump pickup on the inside. I then used a hoist to lift the engine to take the weight off of the engine mounts. The two engine mounts have through bolts that can be loosened. It is not necessary to remove the bolts completely although I did. Now lift the engine about 1 1/2 inches out of the mount. This allowed enough room to turn the pan around and slide it out. Waaay easier than the book method. Good luck and let us know whether this works for you. I had to change a piston because of a dropped intake valve seat because of an overheat. This is how I came to own the vehicle. The dropped valve seat lodged the intake valve open and all the fuel air mixture started igniting inside the intake manifold and destroyed the intake manifold giving way to a huge intake hole which causes the engine to runaway. I'm lucky the seat didn't fall all the way into the cylinder. The walls were spared. I ordered a new piston from the dealership and it came with rings and bearings installed on it.

put in time and remove valve cover, front engine cover, timing belt ,exhaust at manifold, intake manifold and remove head bolts, pull head clean all surfaces replace gasket after head ck for cracks follow specs on bolts and put back together in a shop in would take about 4 to 6 hrs to do .

TORQUE SPECIFICATIONSDescriptionNmLb-FtLb-InEngine Air Cleaner Tube Clamps1.6-2.2-14-19Engine Control Sensor Wiring Through Bolts2.5-3.5-23-30Generator to Bracket Bolt3727-Generator to Cylinder Head Bolt4835-Generator Brace to Upper Intake Manifold Bolts and Nut12-209-14-Intake Manifold Support to Throttle Body8-12-71-106Intake Manifold Support to RH Cylinder Head40-5530-40-Degas Tube to Upper Intake Manifold Bolts8-12-71-106Camshaft Sprocket to Camshaft Bolt50-7037-51-Camshaft Thrust Plate Bolt10-88Coil and Bracket to Cylinder Head Bolt40-5530-40-Connecting Rod Nut31-3923-28-Crankshaft Damper to Crankshaft Bolt125-16593-121-Crankshaft Pulley to Damper (4 Bolts)40-6030-44-Cylinder Head Retaining Bolt(1)(1)-Accelerator Cable Shield Bolts1.4-13Camshaft Position Sensor Housing Retaining Bolt2417-EGR Tube Connector to Exhaust Manifold40-4730-34-EGR Valve to Upper Intake Manifold Bolt20-3015-22-EGR Tube to EGR Valve and Exhaust Manifold35-6526-47-Exhaust Manifold Bolt/Stud20-2515-18-Flywheel to Crankshaft Bolt73-8754-64-Fuel Injection Supply Manifold to Intake Manifold8-12-71-106Throttle Cable Bracket1713-Dual Converter Y Pipe to Exhaust Manifolds34-4725-34-Crankshaft Position Sensor Bolts5-7-45-61Intake Manifold to Cylinder Head Bolt (5)(2)(2)-Main Bearing Cap Bolt75-8556-62-Oil Drain Plug11-169-11-Oil Filter Insert to Cylinder Block27-4020-29-Oil Filter to Oil Filter Adapter(3)(3)-Oil Galley and Cooling Jacket Plugs2014-Oil Level Indicator Tube to Exhaust Manifold Nut16-2012-14-Engine to Transaxle/Torque Converter Assembly Bolts40-6030-44-Torque Converter Nuts27-4620-33-Transmission Range Sensor Nut16-2212-16-Front Sub-Frame-to-Body Bolts77-10357-75-Oil Pressure Sensor16-2212-16-Oil Pump to Cylinder Block Bolt40-5530-40-Power Steering Bracket to Cylinder Head Bolt40-5530-40-Valve Cover to Cylinder Head Bolts/Studs (5)10-14-89-123Right Exhaust Manifold Heat Shield Retaining Bolts8-12-71-106Rocker Arm Seat to Cylinder Head Bolt(4)(4)-Water Outlet Connection to Intake Manifold Bolt10-14-89-123Upper Intake Manifold to Lower Intake Manifold Bolt/Stud20-3015-22-Engine Front Cover to Cylinder Block Bolt (No. 1-10)2518-Engine Front Cover to Cylinder Block Bolt (No. 11-15)10-88Water Pump Pulley to Hub (4 Bolts)20-3015-22-Water Pump to Front Cover Bolt8-12-71-106Wiring Retainer Bracket Nut20-3015-22-Valve Tappet Guide Plate to Cylinder Block10-14-89-123Ignition Coil Bracket40-5530-40-Oil Pan to Cylinder Block Bolt10-14-89-123Water Bypass Tube Nut20-3015-22-Crankshaft Pulley Bolts40-5530-40-

1. Tighten in four steps (refer to illustration in Cylinder Head Installation for tightening sequence):
   • Tighten in sequence to 70-90 Nm (52-66 Lb-Ft)
   • Then back off all bolts 360 degrees
   • Tighten in sequence to 45-55 Nm (34-40 Lb-Ft)
   • Tighten in sequence to 85-99 Nm (63-73 Lb-Ft)
2. Tighten in two steps
   • 20-30 Nm (15-22 Lb-Ft)
   • 26-32 Nm (20-23 Lb-Ft)
3. Advance 3/4 to 1 turn after gasket contacts sealing surface or tighten to 13-15 Nm (10-11 Lb-Ft).
4. Tighten in two steps:
   • 7-15 Nm (6-11 Lb-Ft)
   • 26-38 Nm (20-28 Lb-Ft)
5. Refer to illustration in the Cylinder Head Installation procedure for tightening sequence.

Removal

1. Drain engine cooling system.

1. Disconnect battery ground cable (14301) .

1. Remove engine air cleaner (ACL) (9600) including air cleaner outlet tube (9B659) .

1. Loosen drive belt tensioner (6B209). Remove drive belts (8620) .

1. If LH cylinder head (6049) is being removed, perform the following:
   1. Remove oil filler cap (6766) .
   1. Remove power steering pump front mounting bracket retaining bolts.
   1. Remove generator (GEN) (10346) and belt idler pulley (8678).
   1. Remove power steering pump/generator bracket retaining bolts. Leave hoses connected, place pump/bracket assembly aside in a position to prevent fluid from leaking out.

1. If RH cylinder head is being removed, perform the following:
   1. Remove drive belts .
   1. If equipped with A/C, remove mounting bracket retaining bolts. Leave hoses connected and position A/C compressor (19703) aside.
   1. Remove positive crankcase ventilation valve (PCV valve) (6A666) .

1. Remove upper intake manifold (9424) .

1. Remove valve cover retaining bolts.

1. Remove fuel injection supply manifold (9F792).

1. Remove lower intake manifold as outlined.

1. Remove exhaust manifolds (9430) as outlined.

1. Loosen rocker arm seat retaining bolts enough to allow rocker arm (6564) to be lifted off the push rod (6565) and rotate to one side.

1. Remove push rods . Identify position of each push rod . Push rods should be installed in their original position during assembly.

1. Remove cylinder head retaining bolts and discard.

1. Remove cylinder heads .

1. Remove and discard old head gaskets (6051) .

Installation

1. NOTE: Lightly oil all bolts and stud bolt threads before installation except those specifying special sealant.
   Clean cylinder head, intake manifold , valve cover (6582) and head gasket surfaces. If cylinder head was removed for head gasket replacement, check flatness and sealing areas for scratches of cylinder head and cylinder block gasket surfaces. Refer to Section 03-00 for procedure.
2. Position new head gaskets onto cylinder block (6010) using cylinder head to block dowels (6A008) for alignment.
   
   Head Gasket
   
   
   
   
   
3. Position cylinder heads onto cylinder block .
4. CAUTION: Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.
   -ft).
   
5. For 3.8L non-SC engine, tighten cylinder head retaining bolts in numerical sequence in three steps as follows:
   1. 20 Nm (15 Lb-Ft)
   1. 40 Nm (29 Lb-Ft)
   1. 50 Nm (37 Lb-Ft)
6. CAUTION: Do not loosen all of the bolts at the same time, only work on one bolt at a time or possible damage to engine or leakage may occur.
   In sequence, loosen retaining bolts two to three revolutions and retighten bolts one at a time in the following manner:
   1. Long bolts:
      • 15-25 Nm (11-18 lb-ft).
      • Tighten bolt an additional 85-95 degrees.
      • Go to next bolt in sequence.
   1. Short bolts:
      • 10-20 Nm (7-15 lb-ft).
      • Tighten bolt an additional 85-95 degrees.
      • Go to next bolt in sequence.
      
      
      
      
      
      Item Part Number Description 1 6010 Cylinder Block 2 - Locating Pin (2 Req'd) 3 N802515-S Cylinder Head Bolt (4 Req'd Each Side) 4 6049 Cylinder Head 5 N802516-S Cylinder Head Bolt (4 Req'd Each Side) 6 6A008 Cylinder Head to Block Dowel
7. NOTE: If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check as outlined.
   Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A and install push rods in their original position.
8. For each valve, rotate crankshaft (6303) until valve tappet (6500) rests on the heel (base circle) of the camshaft lobe, before tightening rocker arm seat retaining bolts to 7-15 Nm (5-11 lb-ft) maximum.
9. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford Specification ESR-M99C80-A. Final-tighten the rocker arm seat bolts to 30-40 Nm (22-30 lb-ft). For final tightening, camshaft (6250) may be in any position.
   
10. Install exhaust manifolds as outlined.
11. Install lower intake manifold as outlined.
12. Install fuel injection supply manifold .
13. Position valve cover and new valve cover gasket (6584) on cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 Nm (7-9 lb-ft).
14. Install upper intake manifold .Install spark plugs (12405) , if removed.
15. Connect ignition wires to the spark plugs .
16. If LH cylinder head is being installed, perform the following:
    1. Install oil filler cap.
    1. Install generator/power steering pump mounting bracket.
    1. Install generator .
    1. Install main accessory drive belt tensioner .
    1. Install power steering pump (3A674) .
1. Install power steering pump support bracket.If RH cylinder head is being installed, perform the following:
17. 1. Install positive crankcase ventilation valve .
    1. If equipped with A/C, install A/C compressor mounting brackets (2882) and A/C compressor .
18. Install drive belt and tighten to specification.
19. Connect battery ground cable .
20. Install air cleaner outlet tube.

Need to remove upper intake manifold to reach valve cover close to firewall. 1) The location of spark plugs 456 are under the plastic shield in front of the engine. It takes an 8mm socket to remove the three bolts holding the shield once the shield is removed you will see a coil for each spark plug. Use the 8mm socket and remove the coil and rubber boots. You will now see the spark plug (note there are not any spark plug wires). 2) The location of spark plugs 123 are located to the rear of the eng. You have to remove the air intake manifold in order to get to the spark plus. Remove the throttle wire then remove the other items on top of the intake manifold. 3) Loosen all the bolts holding the manfold. 8mm socket-- I think three in front and three in the middle. Remove the EGR valve mounts so you can slide the manifold out. Disconnet all vacuum lines from manifold and the air filter inlet closet to manifold. Just take a general look and ensure you have all wiring and tubing disconnected then slide the manifold off the eng and EGR valve. NOW MAKE SURE you cover all intake holes (leading into the engine) with paper towels to prevent droping screws etc into the engine. Then follow step 1 above

get the pcm computer checked first for errors.
The 2 knock sensors are bolted into the cylinder block under the intake manifold. The sensors are used only with the 3.7L engine.
http://www.autozone.com/shopping/repairGuide.htm?pageId=0900c15280221909

what are your sysptoms of no start?

96 escort 1.9L




Engine Components
Item Part Number Description 1 6766 Oil Filler Cap 2 6A548 (8 Req'd) Valve Cover Bolt 3 6582 Valve Cover 4 — Exhaust Manifold Shield-to-Exhaust Manifold Nut (4 Req'd) 5 9A462 Exhaust Manifold Shield 6 — Exhaust Manifold Shield Stud (4 Req'd) 7 9430 Exhaust Manifold 8 9454 Exhaust Manifold Nut 9 9448 Exhaust Manifold Gasket 10 — Exhaust Manifold Stud (Fine Thread), Short (4 Req'd) 11 — Exhaust Manifold Stud, Long (1 Req'd) 12 — Exhaust Manifold Stud (Medium Thread), Short (1 Req'd) 13 6518 Valve Spring Retainer Key 14 6514 Valve Spring Retainer 15 6513 Valve Spring and Damper, Intake 16 6C515 Valve Tappet Guide Plate Retainer 17 6571 Valve Stem Seal 18 6513 Valve Spring, Exhaust 19 12405 Spark Plug 20 6269 Camshaft Thrust Plate 21 — Camshaft Thrust Plate Bolt (2 Req'd) 22 — Cup Plug 23 6B273 Camshaft Oil Flow Control Rod 24 6K292 Camshaft Front Seal 25 6256 Camshaft Sprocket 26 6278 Camshaft Sprocket Washer 27 6K252 Camshaft Sprocket Retaining Bolt 28 6L269 Camshaft Sprocket Key (5 x 18) 29 6250 Camshaft 30 6051 Head Gasket 31 6A008 Cylinder Head to Block Dowel 32 6010 Cylinder Block 33 6507 Intake Valve 34 6505 Exhaust Valve 35 6049 Cylinder Head 36 — Intake Manifold Stud (7 Req'd) 37 17A084 Engine Lifting Eye 38 — Engine Lifting Eye Bolt (2 Req'd) 39 9439 Intake Manifold Gasket 40 — Bolt 41 9723 Accelerator Cable Bracket 42 9424 Intake Manifold 43 — Intake Manifold Nut (7 Req'd) 44 9D476 EGR Valve Gasket 45 — Exhaust Gas Recirculation (EGR) Valve Bolt (2 Req'd) 46 9D475 EGR Valve 47 — Fuel Injection Supply Manifold Bolt
(2 Req'd) 48 9F593 Fuel Injector 49 9D930 Fuel Charging Wiring 50 6786 Oil Level Indicator Tube Bracket 51 — Oil Level Indicator Tube Bracket Bolt 52 6754 Oil Level Indicator Tube 53 6750 Oil Level Dipstick 54 9D280 Fuel Injection Supply Manifold 55 — Vacuum Fitting 56 9E498 Main Emission Vacuum Control Connector 57 — Vacuum Tap 58 — Vacuum Hose 59 9B989 Throttle Position Sensor 60 — Screw and Washer 61 9F782 Throttle Position Sensor Gasket 62 — Throttle Body Bolt (4 Req'd) 63 — Idle Air Control (IAC) Valve Bolt
(2 Req'd) 64 9F715 Idle Air Control Valve 65 9F670 Idle Air Control Gasket 66 9E926 Throttle Body 67 9E936 Throttle Body Gasket 68 — Vacuum Fitting 69 — Camshaft Position Sensor Screw 70 6B288 Camshaft Position Sensor 71 8255 Water Hose Connection Gasket 72 — Water Hose Connection Bolt (3 Req'd) 73 8592 Water Hose Connection 74 8575 Water Thermostat 75 6065 Cylinder Head Bolts 76 6500 Valve Tappet 77 6K512 Valve Tappet Guide Plate 78 6564 Rocker Arm 79 6A528 Rocker Arm Seat 80 6A527 Rocker Arm Bolt (8 Req'd) 81 — Ignition Coil Mounting Bracket Bolt
(3 Req'd) 82 18827 Noise Filter Condenser 83 — Ignition Coil Mounting Bolt (4 Req'd) 84 12259 Spark Plug Wire Set 85 12029 Ignition Coil 86 12043 Ignition Coil Mounting Bracket A — Tighten to 5-12 Nm (4-9 Lb-Ft) B — Tighten to 5-7 Nm (3-5 Lb-Ft) C — Tighten to 21-26 Nm (16-19 Lb-Ft) D — Tighten to 2-10 Nm (1.5-7 Lb-Ft) E — Tighten to 8-13 Nm (6-9 Lb-Ft) F — Tighten to 40-55 Nm (30-41 Lb-Ft) G — Tighten to 16-20 Nm (12-15 Lb-Ft) H — Tighten to 20-30 Nm (15-22 Lb-Ft) I — Tighten to 8-10 Nm (6-8 Lb-Ft) J — Tighten to 8-11 Nm (6-9 Lb-Ft) K — Tighten to 23-30 Nm (17-22 Lb-Ft) L — Tighten to 20-40 Nm (15-30 Lb-Ft) M — Tighten to 4.5-7 Nm (3-5 Lb-Ft) N — Tighten to 18-26 Nm (13-19 Lb-Ft)