connectors JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

LATCH
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Disconnect the exterior handle rod at the han-
dle.
(3) Disconnect the lock and lock cylinder rods at
the latch.
(4) Remove the screws and remove the latch
assembly. (Fig. 6)
(5) Disconnect the electrical connectors.
INSTALLATION
(1) Connect the latch electrical connectors.
(2) Install the latch assembly into the door and
install the screws.
(3) Tighten the latch screws to 11 N´m (95 in. lbs.).
(4) Connect the lock cylinder and lock actuator
rods at the latch.
(5) Connect the exterior handle actuator rod at the
handle.
(6) Adjust the latch as needed. (Refer to 23 -
BODY/DOOR - FRONT/LATCH - ADJUSTMENTS)
(7) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 7)
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N´m (30 in.
lbs.).
(5) Test handle and lock cylinder for proper opera-
tion.
LATCH STRIKER
REMOVAL
(1) Remove the bolts. (Fig. 8)
(2) Remove the latch striker and the spacer, if
equipped.
INSTALLATION
(1) Install the striker and spacer, if equipped.
(2) Install the bolts and tighten to 28 N´m (21 ft.
lbs.).
(3) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
Fig. 6 LATCH
1 - LOCK ACTUATOR ROD
2 - PLASTIC COVER
3 - LATCH ASSEMBLY
4 - DOOR
5 - SCREWS
Fig. 7 LATCH ADJUSTMENT SCREW
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
23 - 124 DOOR - FRONTKJ

LOCK CYLINDER
REMOVAL
(1) Remove the exterior handle. (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
REMOVAL)
(2) Remove the clip and remove the lock cylinder
lever and switch, if equipped.
(3) Remove the screw and remove the lock cylin-
der. (Fig. 9)
INSTALLATION
(1) Install the lock cylinder and install the retain-
ing screw.
(2) Install the lock cylinder switch, if equipped,
lever and retaining clip.
(3) Install the exterior handle. (Refer to 23 -
BODY/DOOR - FRONT/EXTERIOR HANDLE -
INSTALLATION)
TRIM PANEL
REMOVAL
(1) Remove the inside handle screw plug and
remove the screw. (Fig. 10)
(2) Remove the pull handle screw.(3) Using a trim stick C-4755 or equivalent, disen-
gage the trim panel clips and remove the trim panel.
(4) Disconnect the electrical connectors and the
inside handle actuator rod. (Fig. 11)
Fig. 8 LATCH STRIKER
1 - B-PILLAR
2 - SPACER
3 - STRIKER
4 - BOLTS (2)
Fig. 9 LOCK CYLINDER
1 - SCREW
2 - LOCK CYLINDER ASSEMBLY
3 - EXTERIOR HANDLE
Fig. 10 TRIM PANEL
1 - ALIGNMENT PIN HOLES
2 - LATCH ACTUATOR ROD
3 - SCREWS (2)
4 - TRIM PANEL CLIPS
5 - INSIDE HANDLE SCREW PLUG
KJDOOR - FRONT 23 - 125
LATCH STRIKER (Continued)

INSTALLATION
(1) Connect the inside handle actuator rod and the
electrical connectors.
(2) Position the trim panel and seat the clips fully.
(3) Instal the screws and install the screw plug.
WATERDAM
REMOVAL
(1) Remove the trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove the door speaker.
(3) Peal waterdam away from inner door panel
and off of the latch linkages (Fig. 12).
INSTALLATION
(1) Position the wire harness and actuator rods
through the holes in the waterdam.
(2) Place waterdam onto the door.
(3) Install the trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Loosen the bolts. (Fig. 13)
(3) Disconnect the runout tube clip and remove the
regulator.
INSTALLATION
(1) Install the regulator assembly.
(2) Tighten the bolts to 9 N´m (80 in. lbs.) using
the sequence shown. (Fig. 14)
(3) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
WINDOW REGULATOR -
ELECTRIC
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Loosen the bolts. (Fig. 15)
(3) Disconnect the runout tube clip.
(4) Disconnect the electrical connector and remove
the regulator.
INSTALLATION
(1) Install the regulator assembly.
(2) Connect the electrical connector.
Fig. 11 TRIM PANEL CONNECTIONS
1 - ELECTRICAL CONNECTORS
2 - ALIGNMENT PINS
3 - LATCH ACTUATOR ROD
4 - TRIM PANEL
Fig. 12 FRONT DOOR WATERDAM
1 - DOOR
2 - LOCK ACTUATOR ROD
3 - INSIDE HANDLE ACTUATOR ROD AND HOLE
4 - ELECTRICAL CONNECTOR
23 - 126 DOOR - FRONTKJ
TRIM PANEL (Continued)

HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOORS
- REAR/DOOR - REMOVAL)
(2) Remove the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
REMOVAL)
(3) Remove the two door hinge bolts from the
inside of the b-pillar.
(4) Remove the exterior bolts attaching the door
hinges to the b-pillar.
INSTALLATION
(1) Install the hinges.
(2) Install the exterior bolts and tighten to 28 N´m
(21 ft. lbs.).
(3) Install the two inner hinge bolts and tighten to
28 N´m (21 ft. lbs.).
(4) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
(5) Install the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION)
(6) Install the door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - INSTALLATION)
LATCH
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - REMOVAL)(2) Disconnect the actuator rods.
(3) Remove the screws and remove the latch
assembly. (Fig. 7)
(4) Disconnect the electrical connectors.
INSTALLATION
(1) Connect the latch electrical connectors.
(2) Install the latch assembly into the door and
install the screws.
(3) Tighten the latch screws to 11 N´m (95 in. lbs.).
(4) Connect the actuator rods.
(5) Install the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - INSTALLATION)
(6) Adjust the latch as needed. (Refer to 23 -
BODY/DOORS - REAR/LATCH - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 8)
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N´m (30 in.
lbs.).
(5) Test handle and lock cylinder for proper opera-
tion.
Fig. 6 GLASS RUN CHANNEL
1 - BOLTS (3)
2 - QUARTER GLASS
3 - GLASS RUN CHANNEL ASSEMBLY
Fig. 7 LATCH
1-LATCH
2 - SCREWS (4)
KJDOORS - REAR 23 - 131
GLASS RUN CHANNEL (Continued)

LATCH STRIKER
REMOVAL
(1) Remove the bolts. (Fig. 9)
(2) Remove the latch striker and the spacer, if
equipped.
INSTALLATION
(1) Install the striker and spacer.
(2) Install the bolts and tighten to 28 N´m (21 ft.
lbs.).
(3) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
TRIM PANEL
REMOVAL
(1) Remove the inside handle screw plug and
remove the screw. (Fig. 10)
(2) Remove the pull handle screw.
(3) Using a trim stick C-4755 or equivalent, disen-
gage the trim panel clips and remove the trim panel.
(4) Disconnect the electrical connectors and the
inside handle actuator rod. (Fig. 11)
INSTALLATION
(1) Connect the inside handle actuator rod and the
electrical connectors.
(2) Position the trim panel and seat the clips fully.
(3) Instal the screws and install the screw plug.
Fig. 8 LATCH ADJUSTMENT SCREW
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
Fig. 9 LATCH STRIKER
1 - C-PILLAR
2 - SPACER
3 - STRIKER
4 - SCREWS
Fig. 10 A REAR TRIM PANEL
1 - WATERDAM
2 - TRIM PANEL CLIP HOLES
3 - INTERIOR HANDLE AND ACTUATOR ROD
4 - SCREWS (2)
5 - TRIM PANEL CLIPS
6 - INTERIOR HANDLE SCREW PLUG
23 - 132 DOORS - REARKJ
LATCH (Continued)

EXTERIOR HANDLE
REMOVAL
(1) Remove the trim panel and waterdam. (Refer
to 23 - BODY/SWING GATE/TRIM PANEL -
REMOVAL)
(2) Disconnect the lock switch and flip-up glass
release electrical connectors.
(3) Unclip the threaded clips and disconnect the
actuator rods. (Fig. 2)
(4) Remove the screws.
(5) Remove the nuts and remove the handle.
INSTALLATION
(1) Install the handle and hold tightly against the
gate and support bracket.
(2) Install the nuts and tighten to 6 N´m (55 in.
lbs.).
(3) Install the screws.
(4) Connect the actuator rods and electrical con-
nectors.
(5) Install the trim panel and waterdam. (Refer to
23 - BODY/SWING GATE/TRIM PANEL - INSTAL-
LATION)
FLIP-UP GLASS
REMOVAL
(1) Open the flip-up glass and disconnect the elec-
trical connectors.(2) Remove the support cylinders. (Refer to 23 -
BODY/SWING GATE/FLIP-UP GLASS SUPPORT
CYLINDER - REMOVAL)
(3) Open the glass to the full travel with the sup-
port cylinders off.
(4) Remove the bolts and remove the glass. (Fig. 3)
INSTALLATION
(1) Install the flip-up glass and install the hinge
bolts.
(2) Install the support cylinders. (Refer to 23 -
BODY/SWING GATE/FLIP-UP GLASS SUPPORT
CYLINDER - INSTALLATION)
(3) Connect the electrical connectors.
(4) Adjust flip-up glass fit if necessary and tighten
the hinge bolts to 7 N´m (60 in. lbs.). (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
FLIP-UP GLASS LATCH
REMOVAL
(1) Remove the trim panel. (Refer to 23 - BODY/
SWING GATE/TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connectors. (Fig. 4)
(3) Using a trim stick C-4755 or equivalent, mark
the location of the latch assembly for installation.
(4) Remove the nuts and remove the latch assem-
bly.
INSTALLATION
(1) Install the latch assembly.
Fig. 2 EXTERIOR HANDLE
1 - LOCK CYLINDER SCREW
2 - LATCH ACTUATOR ROD CONNECTOR
3 - EXTERIOR HANDLE
4 - NUTS (2)
5 - SCREWS (2)
Fig. 3 FLIP-UP GLASS
1 - BOLTS (4)
2 - HINGE MOUNTING HOLES
3 - DEFROSTER WIRE HARNESS
4 - DEFROSTER ELECTRICAL CONNECTOR
5 - FLIPPER GLASS
23 - 136 SWING GATEKJ

(2) Install the nuts and tighten to 12 N´m (9 ft.
lbs.).
(3) Connect the electrical connectors.
(4) Install the trim panel. (Refer to 23 - BODY/
SWING GATE/TRIM PANEL - INSTALLATION)
(5) Adjust the latch to achieve the best glass fit.
(Refer to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECIFICATIONS)
HINGE
REMOVAL
(1) Remove the swing gate. (Refer to 23 - BODY/
SWING GATE/SWING GATE - REMOVAL)
(2) Remove the bolts and remove the hinges.
INSTALLATION
(1) Install the hinges.
(2) Install the bolts and tighten to 31 N´m (23 ft.
lbs.).
(3) Install the swing gate. (Refer to 23 - BODY/
SWING GATE/ SWING GATE - INSTALLATION)
LATCH
REMOVAL
(1) Remove the trim panel and waterdam. (Refer
to 23 - BODY/SWING GATE/TRIM PANEL -
REMOVAL)
(2) Disconnect the electrical connector and actua-
tor rod at the threaded clip. (Fig. 5)(3) Remove the screws and remove the latch.
INSTALLATION
(1) Connect the electrical connector and install the
latch.
(2) Install the screws and tighten to 11 N´m (8 ft.
lbs.).
(3) Connect the actuator rod.
(4) Install the trim panel and waterdam. (Refer to
23 - BODY/SWING GATE/TRIM PANEL - INSTAL-
LATION)
LATCH STRIKER
REMOVAL
(1) Open the gate and remove the screws attaching
the striker to the d-pillar.
INSTALLATION
(1) Install the striker and install the nuts.
(2) Tighten the nuts to 28 N´m (21 ft. lbs.).
(3) Adjust the swing gate as necessary. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
LOCK CYLINDER
REMOVAL
(1) Remove the exterior handle. (Refer to 23 -
BODY/SWING GATE/EXTERIOR HANDLE -
REMOVAL)
Fig. 4 FLIP-UP GLASS LATCH
1 - NUTS (2)
2 - ELECTRICAL CONNECTOR
3 - SWING GATE
4 - ELECTRICAL CONNECTOR
5 - FLIP-UP GLASS LATCHFig. 5 LATCH
1 - SWING GATE
2 - LATCH ASSEMBLY
3 - ELECTRICAL CONNECTOR
4 - SCREWS
KJSWING GATE 23 - 137
FLIP-UP GLASS LATCH (Continued)

(2) Install the three screws.
(3) Install the fuel cap.
GRILLE
REMOVAL
(1) Remove the upper screws. (Fig. 4)
(2) Roll the grille forward and disengage the two
grille hooks under the headlamp units.
(3) Lift the grille forward and up off of the location
tabs at the bottom and remove.
INSTALLATION
(1) Install the grille onto the locating tabs at the
bottom.
(2) Push the grille back and snap into the hooks in
the grille opening reinforcement.
(3) Check that the black welts at the outboard
ends of the grille have a uniform appearance relative
to the fender and install the screws.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Remove the front fascia. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCIA -
REMOVAL)
(3) Disconnect the electrical connectors. (Fig. 5)
(4) Disconnect the rubber side flap push pin con-
nectors.
(5) Remove the seven bolts and remove the grille
opening reinforcement.
(6) Disconnect the headlamp units electrical con-
nectors.
(7) Remove the headlamp units. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL)
INSTALLATION
(1) Install the headlamp units. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(2) Connect the headlamp unit electrical connec-
tors.
(3) Install the grille opening reinforcement and
install the seven bolts.
(4) Connect the rubber side flap and install the
push pin connectors.
(5) Connect the electrical connectors. (Fig. 5)
(6) Install the front fascia. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION)
(7) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
Fig. 3 FUEL FILL DOOR/HOUSING
1 - FUEL FILL DOOR
2 - HOUSING TABS
Fig. 4 GRILLE
1 - GRILLE OPENING REINFORCEMENT
2 - SCREWS (4)
3 - GRILLE CLIPS
23 - 142 EXTERIORKJ
FUEL FILL DOOR/HOUSING (Continued)

FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Remove the wheel flare molding. (Refer to 23 -
BODY/EXTERIOR/FRONT WHEEL OPENING
FLARE MOLDING - REMOVAL)
(2) Remove the five push pin fasteners and remove
the splash shield. (Fig. 6)
INSTALLATION
(1) Install the splash shield and install the five
push pin fasteners.
(2) Install the wheel flare molding. (Refer to 23 -
BODY/EXTERIOR/FRONT WHEEL OPENING
FLARE MOLDING - INSTALLATION)
Fig. 5 GRILLE OPENING REINFORCEMENT
1 - GRILLE OPENING REINFORCEMENT
2 - BOLTS (3)
3 - ELECTRICAL CONNECTORS4 - ELECTRICAL CONNECTOR
5 - BOLTS (3)
6 - BOLT (1)
Fig. 6 FRONT WHEELHOUSE SPLASH SHIELD
1 - FENDER
2 - FLARE BRACKET
3 - PUSH PIN FASTENERS (5)
4 - SPLASH SHIELD
5 - FLARE BRACKET
KJEXTERIOR 23 - 143
GRILLE OPENING REINFORCEMENT (Continued)

(1) Open the glove box.
(2) Remove the two striker screws and remove the
latch striker.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install the striker and install the two screws.
(2) Loosen the screws to adjust if necessary.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL)
(3) Remove the speakers.
(4) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)
(5) Remove the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL)
(6) Remove the four nuts and remove the center
support bracket. (Fig. 6)
(7) Remove the steering column. (Refer to 19 -
STEERING/COLUMN - REMOVAL)
(8) Remove the drivers side cowl trim cover. (Refer
to 23 - BODY/INTERIOR/COWL TRIM COVER -
REMOVAL)
(9) Disconnect the wire harness connector behind
the drivers side cowl trim cover.
(10) Disconnect the green and light blue wire har-
ness bulk connectors at the junction block. (Fig. 1)
(11) Disconnect the electrical connector at the
inner side of the pedal support bracket. (Fig. 2)
(12) Remove the two bolts at the front of the pedal
support bracket. (Fig. 2)
(13) Remove the two bolts from the bottom side of
the pedal support bracket. (Fig. 2)
Fig. 1 JUNCTION BLOCK CONNECTORS
1 - ELECTRICAL CONNECTOR
2 - ELECTRICAL CONNECTOR
3 - PEDAL SUPPORT BRACKET
4 - JUNCTION BLOCK
KJINSTRUMENT PANEL 23 - 149
GLOVE BOX LATCH STRIKER (Continued)