radiator JEEP LIBERTY 2002 KJ / 1.G Owners Manual

(14) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
INSTALLATION
2.4L Engine
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in intake manifold.
(5) Guide each injector into cylinder head. Be care-
ful not to tear injector o-rings.
(6) Push fuel rail down until fuel injectors have
bottomed on shoulders.
(7) Install 2 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 37). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(9) Snap 2 injection wiring harness clips (Fig. 35)
into brackets.
(10) Connect 2 main engine harness connectors at
rear of intake manifold (Fig. 34).
(11) Tighten 5 intake manifold mounting bolts.
Refer to Engine Torque Specifications.
(12) Install PCV valve and hose.
(13) Install thermostat and radiator hose. Fill with
coolant. Refer to Cooling.
(14) Connect necessary vacuum lines to throttle
body.
(15) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(16) Install air duct to throttle body.
(17) Connect battery cable to battery.
(18) Start engine and check for leaks.
3.7L Engine
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in cylinder head.
(5) Guide each injector into cylinder head. Be care-
ful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on cylinder head shoulder.Pushleftfuel rail down until injectors have bot-
tomed on cylinder head shoulder.
(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 6 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body.
(10) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 37). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(11) Connect necessary vacuum lines to throttle
body.
(12) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(13) Install air box to throttle body.
(14) Install air duct to air box.
(15) Connect battery cable to battery.
(16) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and certain ORVR
components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
A check (control) valve is mounted into the top sec-
tion of the 2±piece fuel pump module. Refer to Fuel
Tank Check Valve for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an ORVR system.
Refer to Emission Control System for additional
information.
14 - 24 FUEL DELIVERYKJ
FUEL RAIL (Continued)

NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
(2) Raise the front wheels off the ground.
(3) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(4) Check the fluid level add if necessary.
(5) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(6) Stop the engine and check the fluid level and
refill as required.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(7) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
(8) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
REMOVAL
REMOVAL - 3.7L
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the radiator cross member (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).
(3) Remove the engine cooling fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(4) Remove the fan shroud
(5) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove the power steering high pressure hose
at the pump.
(7) Remove the return hose at the pump.
(8) Remove the three bolts securing the pump to
the bracket thru the holes in the pulley. (Fig. 3)
(9) Remove the pump from the vehicle.
REMOVAL - 2.4L
CAUTION: On vehicles equipped with the 2.4L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the serpentine drive belt.
(3) Remove the power steering high pressure hose
at the pump using care not to remove the flow con-
trol valve.
(4) Remove the return hose at the pump.
Fig. 2 FLUID RESERVOIR - 2.4L
Fig. 3 POWER STEERING PUMP - 3.7L
1 - MOUNTING BOLTS
2 - RESERVOIR
3 - STEEL PULLEY
19 - 18 PUMPKJ
PUMP (Continued)

(5) Remove the two nuts securing the wire loom
behind the pump bracket.
(6) Remove the three bolts securing the pump to
the bracket thru the holes in the pulley. (Fig. 4)
(7) Remove the pump from the vehicle.
INSTALLATION
INSTALLATION - 3.7L
(1) Install the pump to the vehicle.(2) Install the three bolts securing the pump to the
engine. (Fig. 3) Tighten the bolts to 47 N´m (35
ft.lbs.).
(3) Install the power steering hoses.
(4) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Install the fan shroud
(6) Install the engine cooling fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(7) Install the radiator crossmember (Refer to 23 -
BODY/EXTERIOR/RADIATOR CROSSMEMBER -
INSTALLATION).
(8) Refill the power steering fluid and check for
leaks (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE).
INSTALLATION - 2.4L
(1) Install the pump to the vehicle.
(2) Install the three bolts securing the pump to the
engine. (Fig. 4) Tighten the bolts to 47 N´m (35
ft.lbs.).
(3) Install the two nuts securing the wire loom to
the pump bracket.
(4) Install the power steering pressure and supply
hoses.
(5) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Refill the power steering fluid and check for
leaks (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE).
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pump
Bracket to Pump28 21 Ð
Power Steering Pump
Bracket to Engine47 35 Ð
Power Steering Pump
Flow Control Valve75 55 Ð
Power Steering Pump
Pressure Line28 21 Ð
Power Steering Pump
Pressure Line Bracket12 9 105
Fig. 4 POWER STEERING PUMP - 2.4L
1 - MOUNTING BOLTS
2 - PULLEY
KJPUMP 19 - 19
PUMP (Continued)

SPECIAL TOOLS
POWER STEERING PUMP
FLUID COOLER
DESCRIPTION
The power steering fluid cooler is located at the
front of the vehicle. It is mounted to the radiator
lower support just forward of the air-conditioning
condenser and just rearward of the front fascia. The
cooler is positioned so it is in the air flow through the
front fascia of the vehicle (Fig. 5)
OPERATION
The purpose of the power steering fluid cooler is to
keep the temperature of the power steering system
fluid from rising to a level that would affect the per-
formance of the power steering system.
The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the fin/tubes of the cooler is used to extract
the heat from the cooler which it has absorbed from
the power steering fluid flowing through it. The
cooler is placed in series with the power steering
fluid return line, between the steering gear and the
power steering fluid reservoir. This lowers the tem-
perature of the power steering fluid prior to it enter-
ing the power steering fluid reservoir where it is
resupplied to the power steering pump.
REMOVAL
(1) Remove the return line at the gear.
(2) Remove the return line at the reservoir.
(3) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(4) Remove the two cooler mounting bolts. (Fig. 5)
(5) Remove the cooler from the vehicle.
INSTALLATION
(1) Install the cooler to the vehicle.
(2) Install the two cooler mounting bolts. (Fig. 5).
(3) Install the grille (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION).
(4) Install the return line at the reservoir.
(5) Install the return line at the gear.
(6) Refill the power steering fluid and check for
leaks (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE).
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
Fig. 5 FLUID COOLER
1 - FLUID COOLER
2 - MOUNTING BOLTS
19 - 20 PUMPKJ
PUMP (Continued)

HOSES
REMOVAL
REMOVAL - PRESSURE HOSE
(1) Siphon the power steering fluid from the reser-
voir.
(2) Remove the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).
(3) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).
(4) Remove the fan shroud.
(5) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(6) Remove the pressure hose at the pump.
(7) Disconnect the pressure switch electrical con-
nector from the pressure hose.
(8) Remove the pressure hose from the gear.
(9) Remove the pressure hose mounting bracket
bolts from behind the headlamp assembly. (Fig. 6)
(10) Remove the pressure hose from the vehicle
and transfer power steering pressure switch if neces-
sary.
REMOVAL - RETURN HOSE (GEAR TO THE
COOLER)
(1) Siphon the power steering fluid from the reser-
voir.
(2) Remove the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).
(3) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).(4) Remove the fan shroud.
(5) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(6) Remove the return hose from the gear.
(7) Remove the return hose at the cooler.
(8) Remove the return hose mounting bracket bolts
from the front cradle. (Fig. 7)
(9) Remove the return hose from the vehicle.
REMOVAL - RETURN HOSE (RESERVOIR TO
THE COOLER)
(1) Siphon the power steering fluid from the reser-
voir.
(2) Remove the return hose from the pump reser-
voir.
(3) Remove the return hose at the cooler.
(4) Remove the return hose from the vehicle.
INSTALLATION
INSTALLATION - PRESSURE HOSE
(1) Install the pressure hose to the vehicle. (Fig. 8)
(2) Install the pressure hose mounting bracket
bolts behind the headlamp assembly. Tighten to to 12
N´m (9 ft.lbs.).
(3) Install the pressure hose to the gear. Tighten
the hose to28 N´m (21 ft.lbs.).
(4) Install the pressure switch electrical connector.
(5) Install the pressure hose at the pump. Tighten
the hose to28 N´m (21 ft.lbs.).
Fig. 6 MOUNTING BRACKET
1 - HIGH PRESSURE POWER STEERING HOSE
2 - MOUNTING BRACKET
Fig. 7 RETURN HOSE TO COOLER
1 - MOUNTING BRACKETS
2 - FLUID COOLER
3 - PRESSURE SWITCH
4 - RETURN HOSE
KJPUMP 19 - 21

(6) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install the fan shroud.
(8) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(9) Install the radiator crossmember (Refer to 23 -
BODY/EXTERIOR/RADIATOR CROSSMEMBER -
INSTALLATION).
(10) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE (GEAR TO THE
COOLER)
(1) Install the return hose to the vehicle. (Fig. 7)
(2) Install the return hose mounting bracket bolts
to the front cradle.
(3) Install the return hose at the cooler.
(4) Install the return hose at the gear 28 N´m (21
ft.lbs.).
(5) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install the fan shroud.
(7) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(8) Install the radiator crossmember (Refer to 23 -
BODY/EXTERIOR/RADIATOR CROSSMEMBER -
INSTALLATION).
(9) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - RETURN HOSE (RESERVOIR
TO THE COOLER)
(1) Install the return hose to the vehicle.
(2) Install the return hose to the pump reservoir.
(3) Install the return hose at the cooler.
(4) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensing switch is used in the power
steering system. It is mounted on the high-pressure
steering hose. This switch will be used with both
2.4L and 3.7L engines.
OPERATION
The switch is used on both the 2.4L 4±cylinder and
3.7L V-6 engines.
The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
input is provided during periods of high steering
pump load and low engine rpm; such as during park-
ing maneuvers. The PCM increases the idle speed
through the Idle Air Control (IAC) motor. This is
done to prevent the engine from stalling under the
increased load.
When steering pump pressure exceeds 3275 kPa  
690 kPa (475 psi   100 psi), the Normally Closed
(NC) switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.
REMOVAL
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Remove the high pressure power steering
hose(Refer to 19 - STEERING/PUMP/HOSES -
REMOVAL).
(2) Disconnect electrical connector from power
steering pressure switch.
(3) Place a small container or shop towel beneath
switch to collect any excess fluid.
(4) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION
(1) Install power steering switch into power steer-
ing line. (Fig. 9)
(2) Tighten to 9.6 N´m (85 in. lbs.) torque.
Fig. 8 HIGH PRESSURE HOSE ASSEMBLY
1 - HIGH PRESSURE POWER STEERING HOSE
2 - MOUNTING BRACKET
3 - POWER STEERING PRESURE SWITCH
19 - 22 PUMPKJ
HOSES (Continued)

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
FENDER BOLTS 12 9 Ð
FLIP-UP GLASS HINGE BOLTS 7 Ð 60
FRONT DOOR CHECK STRAP NUTS 12 9 Ð
FRONT DOOR CHECK STRAP TO A-PILLAR BOLTS 12 9 Ð
FRONT DOOR GLASS RUN CHANNEL BOLTS 9 Ð 80
FRONT DOOR HINGE TO A-PILLAR BOLTS 28 21 Ð
FRONT DOOR HINGE TO DOOR NUTS 23 17 Ð
FRONT DOOR LATCH SCREW 11 8 Ð
FRONT DOOR LATCH STRIKER SCREWS 28 21 Ð
FRONT DOOR OUTSIDE HANDLE NUTS 6 Ð 55
FRONT DOOR REGULATOR BOLTS 9 Ð 80
FRONT SEAT BACK RECLINER BOLTS 28 21 Ð
FRONT SEAT BOLTS/NUT 43 32 Ð
FRONT SEAT RISER BOLTS 28 21 Ð
FRONT SEAT TRACK BOLTS 28 21 Ð
HOOD HINGE TO BODY BOLTS 28 21 Ð
HOOD HINGE TO HOOD BOLTS 12 9 Ð
HOOD LATCH NUTS 12 9 Ð
HOOD LATCH SUPPORT BOLTS 10 Ð 85
INSTRUMENT PANEL CENTER SUPPORT BRACKET
BOLTS23 17 Ð
INSTRUMENT PANEL HVAC NUTS/BOLTS 6 Ð 55
INSTRUMENT PANEL ROLL DOWN BOLTS 54 40 Ð
INSTRUMENT PANEL TOP BOLTS 28 21 Ð
OUTSIDE MIRROR NUTS 7 Ð 65
RADIATOR CROSSMEMBER BOLTS 12 9 Ð
REAR DOOR CHECK STRAP NUTS 12 9 Ð
REAR DOOR CHECK STRAP TO A-PILLAR BOLTS 12 9 Ð
REAR DOOR GLASS RUN CHANNEL BOLTS 9 Ð 80
REAR DOOR HINGE TO B-PILLAR BOLTS 28 21 Ð
REAR DOOR HINGE TO DOOR NUTS 23 17 Ð
REAR DOOR LATCH SCREW 11 8 Ð
REAR DOOR LATCH STRIKER SCREWS 28 21 Ð
REAR DOOR OUTSIDE HANDLE NUTS 6 Ð 55
REAR SEAT BACK HINGE BOLTS 28 21 Ð
REAR SEAT LATCH/LOCK ASSEMBLY BOLTS 28 21 Ð
REAR SEAT OUTBOARD NUTS 43 32 Ð
REAR SEAT OUTER SEAT CUSHION LEG BOLTS 35 26 Ð
ROOF RACK BOLTS 8 Ð 75
23 - 4 BODYKJ
BODY (Continued)

LATCH
REMOVAL
(1) Remove the grill. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - REMOVAL)
(2) Remove the latch support bracket bolts and
position the latch assembly aside. (Fig. 1)
(3) Remove the two latch nuts.
(4) Disconnect the release cable.
INSTALLATION
(1) Connect the release cable and install the latch
onto the support bracket.
(2) Install the two nuts and tighten to 12 N´m (9
ft. lbs.).
(3) Install the support bracket and the bolts.
(4) Tighten the bolts to 12 N´m (9 ft. lbs.).
(5) Install the grill. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
LATCH RELEASE CABLE
REMOVAL
(1) Remove the battery. (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL)
(2) Remove the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)(3) Remove the powertrain control module. (Refer
to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/POWERTRAIN CONTROL MODULE -
REMOVAL)
(4) Remove the hood release handle. (Refer to 23 -
BODY/HOOD/LATCH RELEASE HANDLE -
REMOVAL)
(5) Disconnect the attaching clips and remove the
cable from the inside.
INSTALLATION
(1) Install the cable from the inside and attach the
retaining clips.
(2) Install the hood latch release handle. (Refer to
23 - BODY/HOOD/LATCH RELEASE HANDLE -
INSTALLATION)
(3) Install the powertrain control module. (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
INSTALLATION)
(4) Install the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - INSTALLATION)
(5) Install the battery. (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION)
SUPPORT CYLINDER
REMOVAL
(1) Open the hood and support.
(2) Release the upper and lower clips.
(3) Remove the support cylinder.
INSTALLATION
(1) Install the support cylinder over the ball studs
with the thin end down.
(2) Install the retaining clips and remove the sup-
port from the hood.
LATCH RELEASE HANDLE
REMOVAL
(1) Remove the cowl trim panel. (Refer to 23 -
BODY/INTERIOR/COWL TRIM COVER -
REMOVAL)
(2) Remove the three screws and remove the han-
dle.
(3) Disconnect the hood release cable.
INSTALLATION
(1) Connect the hood release cable to the handle.
(2) Install the handle and install the three screws.
(3) Install the cowl trim cover. (Refer to 23 -
BODY/INTERIOR/COWL TRIM COVER - INSTAL-
LATION)
Fig. 1 RADIATOR CROSSMEMBER
1 - CROSSMEMBER
2 - BOLTS (2)
3 - BOLTS (4)
4 - BOLTS (2)
5 - HOOD LATCH SUPPORT
23 - 120 HOODKJ

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL............................140
INSTALLATION........................140
COWL GRILLE
REMOVAL............................140
INSTALLATION........................140
EXTERIOR NAME PLATES
REMOVAL............................140
INSTALLATION........................141
FRONT FENDER
REMOVAL............................141
INSTALLATION........................141
FUEL FILL DOOR/HOUSING
REMOVAL............................141
INSTALLATION........................141
GRILLE
REMOVAL............................142
INSTALLATION........................142
GRILLE OPENING REINFORCEMENT
REMOVAL............................142
INSTALLATION........................142FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL............................143
INSTALLATION........................143
LUGGAGE RACK
REMOVAL............................144
INSTALLATION........................144
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL............................144
INSTALLATION........................144
SIDE VIEW MIRROR
REMOVAL............................145
INSTALLATION........................145
FRONT WHEEL OPENING FLARE MOLDINGS
REMOVAL............................145
INSTALLATION........................145
REAR WHEEL OPENING FLARE MOLDINGS
REMOVAL............................145
INSTALLATION........................145
RADIATOR CROSSMEMBER
REMOVAL............................146
INSTALLATION........................146
BODY SIDE MOLDINGS
REMOVAL
(1) Using a trim stick C-4755 or equivalent,
remove and discard the molding from the outside of
the door.
INSTALLATION
(1) Thoroughly clean all residue from the body side
molding attachment area of the door.
(2) Wipe area clean with a 50% solution of water
and alcohol and wipe dry.
(3) Apply new body side molding using the locators
in the door and apply pressure of approximately 40
p.s.i. over the entire surface of the molding.
COWL GRILLE
REMOVAL
(1) Remove the hood seal.
(2) Remove the wiper arms. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(3) Remove the four plastic retainers and remove
the cowl grill.
INSTALLATION
(1) Position the cowl grill and engage the nine
clips to the bottom of the windshield.
(2) Install the five plastic retainers.
(3) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
(4) Install the hood seal.
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Apply a length of masking tape on the body,
parallel to the top edge of the nameplate to use as a
guide, if necessary.
(2) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun. Do not exceed 52ÉC
(120ÉF) when heating emblem.
(3) Using a trim stick C-4755 or equivalent, behind
the emblem to separate the adhesive backing from
the body.
23 - 140 EXTERIORKJ

(4) Position the door flare and seat the clips.
(5) Install five new rivets through the inside sur-
face of the door attaching the flare to the door.
RADIATOR CROSSMEMBER
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Remove the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)(3) Remove the bolt securing the washer bottle to
the crossmember.
(4) Remove the bolts and remove the hood latch
support. (Fig. 14)
(5) Remove the bolts and remove the crossmember.
INSTALLATION
(1) Install the crossmember and install the bolts.
(2) Tighten the bolts to 10 N´m (85 in. lbs.).
(3) Install the hood latch support and install the
bolts.
(4) Tighten the bolts to 10 N´m (85 in. lbs.).
(5) Install the hood latch. (Refer to 23 - BODY/
HOOD/LATCH - INSTALLATION)
(6) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
(7) Install the bolt securing the washer bottle to
the crossmember and tighten to 10 N´m (85 in. lbs.).
Fig. 12 REAR WHEEL OPENING FLARE MOLDINGS
1 - D-PILLAR
2 - RIVETS (10)
3 - REAR DOOR FLARE MOLDING
4 - REAR FLARE MOLDING
5 - REAR FASCIA
Fig. 13 FLARE EXTENSION
1 - RIVETS (3)
2 - FLARE EXTENSION AND DOOR SILL
Fig. 14 RADIATOR CROSSMEMBER
1 - CROSSMEMBER
2 - BOLTS (2)
3 - BOLTS (4)
4 - BOLTS (2)
5 - HOOD LATCH SUPPORT
23 - 146 EXTERIORKJ
REAR WHEEL OPENING FLARE MOLDINGS (Continued)