JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

GAP AND FLUSH
SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION FIGURE
FRONT QUADRANT ( 105 )
REAR QUADRANT ( 106 )
23 - 116 BODY STRUCTUREKJ

Fig. 105 GAP & FLUSH/FRONT QUADRANT
NOTE:
All measurements are in mm.
U/F = Under Flush
DIMENSION GAP FLUSH DIMENSION GAP FLUSH
A 6.0 +/- 2.0 O/F 12.0 +/- 2.0 E 5.0 +/- 1.5 O/F 3.0 +/- 1.5
B 5.0 +/- 1.0 O/F 0.5 +/- 1.5 F 6.0 +/- 2.0 U/F 18.5 +/- 1.5
C 6.0 +/- 1.5 O/F 3.0 +/- 2.0 G 5.0 +/- 1.5 O/F 3.0 +/- 1.5
D 5.0 +/- 1.5 O/F 5.0 +/- 1.5 H 6.0 +/- 2.0 U/F 18.5 +/- 1.5
KJBODY STRUCTURE 23 - 117
GAP AND FLUSH (Continued)

Fig. 106 GAP & FLUSH/REAR QUADRANT
NOTE:
All measurements are in mm.
U/F = Under Flush
DIMENSION GAP FLUSH DIMENSION GAP FLUSH
I 5.0 +/- 1.0 0.0 +/- 1.5 M 6.0 +/- 1.5 U/F 4.7 +2.5/-1.0
J 5.0 +/- 1.0 0.0 +/- 1.5 N 6.0 +/- 1.5 U/F 4.0 +2.5/-1.0
K 5.0 +/- 1.0 0.0 +/- 1.5 O 6.0 +/- 1.5 Ð
L 5.0 +/- 1.0 0.0 +/- 1.5 P 5.0 +/- 1.0 U/F 0.5 +/- 1.0
23 - 118 BODY STRUCTUREKJ
GAP AND FLUSH (Continued)

HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL............................119
INSTALLATION........................119
HOOD
REMOVAL............................119
INSTALLATION........................119
ADJUSTMENTS
ADJUSTMENT.......................119
LATCH
REMOVAL............................120INSTALLATION........................120
LATCH RELEASE CABLE
REMOVAL............................120
INSTALLATION........................120
SUPPORT CYLINDER
REMOVAL............................120
INSTALLATION........................120
LATCH RELEASE HANDLE
REMOVAL............................120
INSTALLATION........................120
HINGE
REMOVAL
NOTE: It is not necessary to remove the hood to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Raise and support hood.
(2) Using a grease pencil or equivalent, mark posi-
tion of hinge.
(3) Remove hood support cylinder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLINDER - REMOVAL)
(4) Remove nuts attaching hinge to hood.
(5) Remove bolts attaching hinge to body.
(6) Separate hinge from vehicle.
INSTALLATION
(1) Position hinge on vehicle and align reference
marks.
(2) Install bolts attaching hinge to body and
tighten to 28 N´m (21 ft. lbs.).
(3) Install nuts attaching hinge to hood 12 N´m (9
ft. lbs.).
(4) Install hood hinge support cylinder. (Refer to
23 - BODY/HOOD/SUPPORT CYLINDER - INSTAL-
LATION)
HOOD
REMOVAL
(1) Raise hood.
(2) Using a grease pencil or equivalent, mark loca-
tion of hood hinges on hood for installation align-
ment.
(3) Remove bolts attaching hinges to hood.
(4) With the aid of a helper, remove hood from
vehicle.
INSTALLATION
(1) Position hood on hinges.
(2) Install bolts finger-tight.
(3) Align hinges with installation reference marks
and tighten bolts to 12 N´m (9 ft. lbs.).
(4) Inspect hood for proper alignment and adjust
as necessary.
ADJUSTMENTS
ADJUSTMENT
(1) If hood is low in relation to cowl panel, insert
shims between hinge and hood.
(2) Adjust hood bumper in or out to adjust hood-
to-fender height alignment.
(3) Adjust the hood latch as necessary. Tighten the
nuts to 11 N´m (8 ft. lbs.).
(4) Align the latch striker so that striker enters
the latch squarely and without binding.
KJHOOD 23 - 119

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

DOOR - FRONT
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL............................121
INSTALLATION........................121
DOOR
REMOVAL............................122
INSTALLATION........................122
DOOR GLASS
REMOVAL............................122
INSTALLATION........................122
EXTERIOR HANDLE
REMOVAL............................123
INSTALLATION........................123
GLASS RUN CHANNEL
REMOVAL............................123
INSTALLATION........................123
HINGE
REMOVAL............................123
INSTALLATION........................123
LATCH
REMOVAL............................124
INSTALLATION........................124ADJUSTMENTS
ADJUSTMENT.......................124
LATCH STRIKER
REMOVAL............................124
INSTALLATION........................124
LOCK CYLINDER
REMOVAL............................125
INSTALLATION........................125
TRIM PANEL
REMOVAL............................125
INSTALLATION........................126
WATERDAM
REMOVAL............................126
INSTALLATION........................126
WINDOW REGULATOR - MANUAL
REMOVAL............................126
INSTALLATION........................126
WINDOW REGULATOR - ELECTRIC
REMOVAL............................126
INSTALLATION........................126
CHECK STRAP
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Remove screws attaching door check to A-pillar.
(3) Remove the two nuts and remove the door
check strap. (Fig. 1)
INSTALLATION
NOTE: Make sure the proper orientation of the
check strap is maintained using the ªRº and ªLº on
the top.
(1) Install the check strap through the speaker
hole.
(2) Install the nuts and tighten to 12 N´m (9 ft.
lbs.).
(3) Connect the strap to the A-pillar and tighten
the bolts to 12 N´m (9 ft. lbs.).
(4) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
Fig. 1 CHECK STRAP
1 - NUTS
2 - CHECK STRAP
3 - SPEAKER OPENING
KJDOOR - FRONT 23 - 121

DOOR
REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the A-pillar.
(2) Support the door with a suitable lifting device.
(3) Remove the bolts attaching the check strap to
the a-pillar.
NOTE: The epoxy washers should not be removed
from the hinge. If the washers are removed the door
may have to be re-adjusted.
(4) Remove the nuts attaching the door hinges to
the door. (Fig. 2)
INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the nuts and washers if they were
removed previously and tighten to 23 N´m (17 ft.
lbs.).
(3) Connect the door wire harness electrical con-
nector.
(4) Connect the check strap to the a-pillar and
install the bolts.
(5) Tighten the check strap bolts to 12 N´m (9 ft.
lbs.).(6) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
DOOR GLASS
REMOVAL
(1) Remove the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - REMOVAL)
(2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Raise the glass to the position shown and using
a long flat blade or hook type tool, disengage clips
attaching glass retainer to regulator lift plate. (Fig.
3)
(4) Disconnect the glass from the regulator lift
plate and re-install the clips.
(5) Rotate the top of the glass toward the front
and remove the glass from the window opening.
INSTALLATION
(1) Install the glass through the window opening
and align the mounting plate to the lift plate.
(2) Engage the glass to the regulator lift plate.
(3) Install the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - INSTALLATION)
(4) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
Fig. 2 HINGES
1 - NUTS (4)
2 - EPOXY WASHERS (2) (NOT REMOVABLE)
3 - HINGES
4 - DOOR
Fig. 3 DOOR GLASS/REGULATOR
1 - DOOR GLASS ATTACHMENT CLIP (2)
2 - DOOR OPENING
3 - REGULATOR LIFT PLATE
4 - DOOR GLASS
23 - 122 DOOR - FRONTKJ

EXTERIOR HANDLE
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Disconnect the lock switch electrical connector,
if equipped. (Fig. 4)
(3) Disconnect the handle rod at the handle and
the key cylinder rod at the latch.
(4) Remove the screws.
(5) Remove the nuts and remove the handle.
INSTALLATION
(1) Position the handle on the door and slide fully
toward the rear of the door.
(2) Install the nuts and tighten to 6 N´m (55 in.
lbs.).
(3) Install the screws and tighten to 6 N´m (55 in.
lbs.).
(4) Connect the handle rod at the handle and the
key cylinder rod at the latch.
(5) Connect the lock switch electrical connector, if
equipped.
(6) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
GLASS RUN CHANNEL
REMOVAL
(1) Position the window into the down position.
(2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)(3) Remove the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - REMOVAL)
(4) Remove the front and rear bolts. (Fig. 5)
(5) Peal the weatherstrip out of the door frame
and remove the run channel through the window
opening.
INSTALLATION
(1) Install the run channel through the window
opening and into the door frame.
(2) Install the front, rear bolts and tighten to 9
N´m (80 in. lbs.).
(3) Install the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - INSTALLATION)
(4) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
hinge location and remove the bolts.
INSTALLATION
(1) Install the hinges and bolts.
(2) Tighten bolts to 28 N´m (21 ft. lbs.).
(3) Install the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - INSTALLATION)
Fig. 4 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - NUTS
3 - SCREWS
4 - ELECTRICAL CONNECTOR
Fig. 5 GLASS RUN CHANNEL
1 - WINDOW OPENING
2 - REAR BOLTS (2)
3 - GLASS RUN CHANNEL
4 - FRONT BOLTS (2)
KJDOOR - FRONT 23 - 123

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)