8W 01 1 JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

BODY STRUCTURE
TABLE OF CONTENTS
page page
ASSEMBLY
SPECIFICATIONS
SPECIFICATION.......................6
WELD AND STRUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS........................9SEALER LOCATIONS
SPECIFICATIONS.......................87
OPENING DIMENSIONS
SPECIFICATIONS......................111
GAP AND FLUSH
SPECIFICATIONS......................116
ASSEMBLY
SPECIFICATIONS
SPECIFICATION
INDEX
DESCRIPTION FIGURE
COMPLETE BODY STRUCTURE VIEWS ( 1 )
BODY STRUCTURE - SECTIONS ( 2 )
23 - 6 BODY STRUCTUREKJ

Fig. 1 COMPLETE BODY STRUCTURE VIEWS
KJBODY STRUCTURE 23 - 7
ASSEMBLY (Continued)

Fig. 2 BODY STRUCTURE - SECTIONS
23 - 8 BODY STRUCTUREKJ
ASSEMBLY (Continued)

WELD AND STRUCTURAL
ADHESIVE LOCATIONS
SPECIFICATIONS
Fig. 3 BODY IN WHITE - SECTIONS
KJBODY STRUCTURE 23 - 9

INDEX
DESCRIPTION FIGURE
FRONT END ASSEMBLY
INNER FRONT PANELS ( 4 )
INNER WHEELHOUSE ASSEMBLIES ( 5 )
INNER WHEEL HOUSES & LOWER REINFORCEMENTS ( 6 )
FRONT BUMPER CROSSMEMBER ASSEMBLY ( 7 )
INNER FRONT WHEELHOUSE ASSEMBLY ( 8 )
FRONT INNER RAIL ASSEMBLY ( 9 )
FRONT INNER RAILS AND BRACKET WELD POINTS ( 10 )
FRONT INNER RAILS AND BRACKET WELD POINTS ( 11 )
FRONT OUTER RAIL & TORQUE BOX ( 12 )
FRONT OUTER RAIL ASSEMBLIES ( 13 )
FRONT OUTER RAILS AND BRACKET WELD POINTS ( 14 )
INNER FRONT WHEELHOUSE ASSEMBLY - COMPLETE ( 15 )
INNER FRONT WHEELHOUSE TO RAILS ( 16 )
COWL SIDE PANEL ASSEMBLIES ( 17 )
PLENUM ASSEMBLY ( 18 )
PLENUM BAFFLE & PLENUM CLOSURE PANEL ( 19 )
PLENUM BAFFLE & STEERING COLUMN REINFORCEMENT ( 20 )
FRONT END ASSEMBLY/UNDERBODY
FLOOR PAN ASSEMBLY ( 21 )
FLOOR PAN AND DASH PANEL ( 22 )
DASH PANEL AND PLENUM ( 23 )
WHEELHOUSE, FLOOR PAN, DASH PANEL AND PLENUM ASSEMBLY ( 24 )
COWL SIDE PANEL ( 25 )
REAR FRAME RAILS
REAR FRAME RAIL ASSEMBLY ( 26 )
REAR CONTROL ARM AND SHOCK MOUNTING BRACKETS ( 27 )
REAR SPRING MOUNTING BRACKETS AND REINFORCEMENTS ( 28 )
REAR SPRING REINFORCEMENTS, SHOCK MOUNTING, FUEL PASS AND EXHAUST
HANGER BRACKET(29)
REAR WHEELHOUSE ASSEMBLIES ( 30 )
FRONT AND REAR RAIL REINFORCEMENTS ( 31 )
REAR FLOOR PAN ASSEMBLY
REAR FLOOR PAN, COMPRESSION AND ANCHOR PLATE ASSEMBLY ( 32 )
SWING GATE AND BUMPER REINFORCEMENT ( 33 )
FLOOR PAN AND REAR RAIL ASSEMBLIES ( 34 )
FLOOR PAN AND REAR RAIL ADHESIVE LOCATIONS ( 35 )
FLOOR PAN AND REAR RAIL WELD LOCATIONS ( 36 )
REAR FLOOR PAN, CROSSMEMBERS AND FUEL TANK REINFORCEMENTS ( 38 )
23 - 10 BODY STRUCTUREKJ
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

DESCRIPTION FIGURE
FULL FLOOR PAN ASSEMBLY
FULL FLOOR PAN ASSEMBLIES ( 39 )
FLOOR PAN AND RAIL ASSEMBLY ADHESIVE LOCATIONS ( 40 )
FLOOR PAN AND RAIL ASSEMBLY WELD LOCATIONS ( 41 )
FLOOR PAN, BODY SIDE SILL, COWL SIDE PANEL AND CROSSMEMBERS ( 42 )
WHEELHOUSE ADHESIVE LOCATIONS ( 43 )
WHEELHOUSE WELD LOCATIONS ( 44 )
BODY SIDE PANELS AND SUB ASSEMBLIES
A-PILLAR AND HEADER MOUNTING REINFORCEMENTS ( 45 )
B-PILLAR REINFORCEMENTS ( 46 )
C-PILLAR AND SEAT BACK MOUNTING REINFORCEMENTS ( 47 )
D-PILLAR REINFORCEMENTS ( 48 )
TAIL LAMP MOUNTING PANEL AND GATE STRIKER REINFORCEMENT ( 49 )
TAIL LAMP MOUNTING PANEL AND TAIL LAMP EXTENSION ( 50 )
SWING GATE OPENING PANEL AND ROOF HEADER ( 51 )
BODY SIDE PANELS
BODY SIDE PANEL ASSEMBLY ( 52 )
BODY SIDE OUTER, INNER FENDER REINFORCEMENT AND FENDER ASSEMBLY ( 53 )
BODY SIDE OUTER AND INNER PANELS; A-PILLAR ( 54 )
LOWER INNER BODY SIDE PANELS AND UPPER A-PILLARS ( 55 )
BODY SIDE PANEL ASSEMBLIES AND B-PILLAR. ( 56 )
BODY SIDE PANEL ASSEMBLIES AND C-PILLAR REINFORCEMENT ( 57 )
QUARTER WINDOW OPENING; SEAT BACK ATTACH REINFORCEMENT; C-PILLAR
REINFORCEMENT(58)
BODY SIDE PANEL ASSEMBLIES AND OUTER REAR WHEELHOUSES ( 59 )
OUTER REAR WHEELHOUSE WELDS AND ADHESIVE LOCATIONS ( 60 )
D-PILLAR AND TAIL LAMP ASSEMBLY WELD AND ADHESIVE LOCATIONS ( 61 )
SWING GATE STRIKER REINFORCEMENT WELDS AND ADHESIVE LOCATIONS ( 62 )
REAR WHEELHOUSE WELDS AND TAIL LAMP ADHESIVE LOCATIONS ( 63 )
FENDER ASSEMBLIES
INNER FENDER REINFORCEMENT AND GUSSETS ( 64 )
INNER FENDER REINFORCEMENT, GUSSETS, PLENUM AND WHEELHOUSES ( 65 )
INNER FENDER REINFORCEMENT AND WHEELHOUSES ( 66 )
PLENUM ASSEMBLY AND INNER SIDE PANELS ( 67 )
ROOF PANEL ASSEMBLIES
ROOF PANEL ASSEMBLY ( 68 )
ROOF PANEL AND BODY SIDE WELD AND ADHESIVE LOCATIONS ( 69 )
ROOF PANEL AND BODY SIDE WELD AND ADHESIVE LOCATIONS - SUNROOF
EQUIPPED(70)
ROOF AND HEADER PANEL ASSEMBLY ( 71 )
KJBODY STRUCTURE 23 - 11
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

DESCRIPTION FIGURE
BODY SIDE PANELS & FLOOR PAN ASSEMBLIES
BODY SIDE PANEL AND FLOOR PAN ASSEMBLIES ( 72 )
BODY SIDE SILLS AND REAR WHEELHOUSES ( 73 )
ROOF HEADER AND WHEELHOUSE WELDS AND ADHESIVE LOCATIONS ( 74 )
SWING GATE OPENING PANEL; GATE STRIKER REINFORCEMENT; D-PILLAR
REINFORCEMENT ADHESIVE AND WELD LOCATIONS(75)
SWING GATE OPENING PANEL; D-PILLAR LOWER TO FLOOR GUSSET; GATE
OPENING REINFORCEMENT(76)
REAR FLOOR PAN AND CROSSMEMBER; TAIL LAMP MOUNTING; SWING GATE
OPENING PANEL;(77)
23 - 12 BODY STRUCTUREKJ
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

FRONT END ASSEMBLY
Fig. 4 INNER FRONT PANELS
KJBODY STRUCTURE 23 - 13
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

Fig. 5 INNER WHEEL HOUSES
23 - 14 BODY STRUCTUREKJ
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

Fig. 6 INNER WHEEL HOUSES
KJBODY STRUCTURE 23 - 15
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)