Jeep - Liberty :: 2002 / 3.7l - Overheats Sludge In Coolant Reservoir


Jul 22, 2015

It has 197k and change.It's not throwing any codes whatsoever. I can drive it all day and it wont overheat as long as I keep it under 2000 rpm.If I take it over 2000 rpm, it slowly heats up, but I can cool it down by slowing down. I can do like 50 mph max without it threatening to overheat. I've never let it get above 3/4 without pulling over and letting it cool off (I know how heads like to warp and crack).

Rubbery sludge in coolant reservoir (almost positive it's oil) but absolutely NO coolant in the oil, there never has been. I do all the oil changes myself and check it quite often. I've been keeping the reservoir full but it loses coolant daily (no leaks on ground anywhere, ever. I've already removed the reservoir and cleaned it out several times, but since it has more than one chamber it's almost impossible to fully clean without replacing. The hose that runs from the top chamber to the bottom blows off from time to time (I finally put hose clamps on it). I've flushed the cooling system several times but still the sludge comes back. I've removed and cleaned the thermostat (still good) and housing (had very little sludge). I flushed out the heater core but the heat is still weak.

Makes a loud whistling noise at idle, the noise literally stops every time I give it gas. (this is where I was thinking Intake Manifold Gasket, maybe vacuum leak) You gotta love these plastic manifolds. BUT it's idling low (650 rpm once fully warmed up) not bogging or sputtering whatsoever. Fans are working completely fine. It loses oil but again, no leaks on the ground whatsoever. I thought at first it was burning it (high mileage, worn piston rings) until I noticed the coolant reservoir was gunked (wasn't very long and I know I didn't mix different kinds. I check everything (more than regularly) and it loses quite a bit of oil.

Before everyone says head gasket, it isn't losing much power (if any at all), no white exhaust, and as mentioned before there's no coolant in the oil.Whatever it is, I can repair it myself but before I tear this thing a new one replacing gaskets and seals I'd like to be completely sure.

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Returned to the dealer and they did all their tests and everything OK. A while later again overheating and returned to the dealer. Their tests again showed no problem, but the mechanic noticed the aux. the fan did not come on when AC turned on. He ran his own tests and decided either the switch or the relay for the fan was faulty, with the switch more likely. They ordered a new switch; the switch didn't?t fit. Called the supplier and requested the correct switch and again the switch didn't?t fit. The mechanic said he could file the prongs to make it fit and did so.

The jeep ran excellent for a few months. In Feb. had to overheat again, this time the dealer found sludge from the old mix of correct/incorrect coolant and flushed system twice. Jeep ran OK for a couple months then again overheating. This time it made it over the mountains fine but driving along flat I-5 south of Redding it overheated. We stopped and after the reservoir stopped boiling (10 min) the temp gauge was fine. We drove for 1-2 hrs. and heats up again. This keeps up till we get home, 400 mi. later. The dealer does his tests and everything fine. I tell them the aux. the fan seems to be randomly shutting off on its own but it does not act up for them so there is no problem. Could the replacement coolant temperature switch for the aux fan not be compatible with the 2002 Jeep?

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In seems to me that there is some kind of internal issue, e.g. intake manifold gasket, where the fluids are mixing. FWIW, I don't see any sign of external coolant leakage. Do the 3100s have any known issues in this area? I suggested my friend have the Buick dealer pressure test it (when it's cold), and go from there.

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