JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

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)

(3) Tighten the bolts to 9 N´m (80 in. lbs.) using
the sequence shown. (Fig. 16)
(4) Connect the runout tube clip.(5) Install the glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
Fig. 13 FRONT DOOR REGULATOR - MANUAL
1 - BOLTS
2 - BOLTS
3 - RUNOUT TUBE
4 - RUNOUT TUBE CLIP
5 - BOLTS
Fig. 14 REGULATOR TIGHTENING SEQUENCE
Fig. 15 WINDOW REGULATOR - ELECTRIC
1 - BOLTS (3)
2 - BOLT
3 - BOLT
4 - RUNOUT TUBE CLIP
5 - BOLTS (2)
6 - REGULATOR ASSEMBLY
Fig. 16 REGULATOR TIGHTENING SEQUENCE
KJDOOR - FRONT 23 - 127
WINDOW REGULATOR - ELECTRIC (Continued)

DOORS - REAR
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL............................128
INSTALLATION........................128
DOOR
REMOVAL............................129
INSTALLATION........................129
DOOR GLASS
REMOVAL............................129
INSTALLATION........................129
EXTERIOR HANDLE
REMOVAL............................130
INSTALLATION........................130
GLASS RUN CHANNEL
REMOVAL............................130
INSTALLATION........................130
HINGE
REMOVAL............................131
INSTALLATION........................131
LATCH
REMOVAL............................131INSTALLATION........................131
ADJUSTMENTS
ADJUSTMENT.......................131
LATCH STRIKER
REMOVAL............................132
INSTALLATION........................132
TRIM PANEL
REMOVAL............................132
INSTALLATION........................132
WATERDAM
REMOVAL............................133
INSTALLATION........................133
WINDOW REGULATOR - MANUAL
REMOVAL............................133
INSTALLATION........................133
WINDOW REGULATOR - ELECTRIC
REMOVAL............................134
INSTALLATION........................134
CHECK STRAP
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Remove screws attaching door check to b-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 b-pillar and tighten
the bolts to 12 N´m (9 ft. lbs.).
(4) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
Fig. 1 CHECK STRAP
1 - NUTS
2 - CHECK STRAP
3 - SPEAKER OPENING
23 - 128 DOORS - REARKJ

DOOR
REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the b-pillar.
(2) Disconnect the check strap from the b-pillar.
(Refer to 23 - BODY/DOORS - REAR/CHECK STRAP
- REMOVAL)
(3) Support the door with a suitable lifting device.
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 b-pillar.
(2) Install the nuts, washers 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 b-pillar. (Refer
to 23 - BODY/DOORS - REAR/CHECK STRAP -
INSTALLATION)(5) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
DOOR GLASS
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Raise the glass and line up the lift plate clip
with the hole in the door panel shown. (Fig. 3)
(3) Using a long flat blade or hook type tool, dis-
engage the clip attaching glass retainer to regulator
lift plate.
(4) Disconnect the glass from the regulator lift
plate and re-install the clip.
(5) Position the glass into the bottom of the door.
(6) Remove the glass division bar bolt. (Fig. 4)
(7) Twist the division bar towards the inside of the
door and disengage the door glass.
(8) Remove the glass from the window opening.
INSTALLATION
(1) Install the glass through the window opening.
(2) Position the front of the glass into the glass
run channel.
Fig. 2 HINGES
1 - DOOR
2 - HINGES
3 - EPOXY WASHERS (2) (NOT REMOVABLE)
4 - NUTS
Fig. 3 DOOR GLASS POSITION
1 - GLASS DIVISION BAR
2 - DOOR PANEL SIGHT HOLE
3 - DOOR GLASS
KJDOORS - REAR 23 - 129

(3) Twist the glass division bar towards the inside
of the door and position the door glass into the rear
run channel.
(4) Lift glass up in the window and engage the pin
into the regulator lift plate.
(5) Raise the glass into the closed position and
install the division bar bolt.
(6) Tighten the bolt to 9 N´m (80 in. lbs.).
(7) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
EXTERIOR HANDLE
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Disconnect the actuator rod.
(3) Remove the nuts and remove the handle. (Fig.
5)
INSTALLATION
(1) Install the handle.
(2) Install the nuts and tighten to 6 N´m (55 in.
lbs.).
(3) Connect the actuator rod.
(4) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
GLASS RUN CHANNEL
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - REMOVAL)
(2) Remove the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/REAR DOOR
OUTER BELT MOLDING - REMOVAL)
(3) Remove the front and rear bolts. (Fig. 6)
(4) Peal the weatherstrip and quarter glass out of
the door frame and remove the run channel through
the window opening as an assembly.
INSTALLATION
(1) Install the run channel and quarter glass
assembly 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/REAR DOOR
OUTER BELT MOLDING - INSTALLATION)
(4) Install the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - INSTALLATION)
Fig. 4 GLASS DIVISION BAR
1 - STATIONARY DOOR GLASS
2 - DIVISION BAR BOLT (1)
3 - DOOR
4 - GLASS DIVISION BAR
Fig. 5 EXTERIOR HANDLE
1 - NUTS (2)
2 - EXTERIOR HANDLE
23 - 130 DOORS - REARKJ
DOOR GLASS (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)

WATERDAM
REMOVAL
(1) Remove the trim panel. (Refer to 23 - BODY/
DOORS - REAR/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/
DOORS - REAR/TRIM PANEL - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - REMOVAL)
(2) Remove the bolts. (Fig. 13)
(3) Disconnect the runout tube clip and remove the
regulator.
INSTALLATION
(1) Loosely install the bolts onto the regulator
assembly.
(2) Install the regulator assembly.
Fig. 11 A REAR DOOR TRIM PANEL CONNECTIONS
1 - TRIM PANEL
2 - INTERIOR LATCH HANDLE
3 - LATCH ACTUATOR ROD
Fig. 12 REAR DOOR WATERDAM
1 - WATERDAM
2 - LOCK ACTUATOR RODS
3 - LOCK ACTUATOR ROD AND HOLES
4 - DOOR
5 - INSIDE HANDLE ACTUATOR ROD AND HOLES
Fig. 13 WINDOW REGULATOR - MANUAL
1 - RUNOUT TUBE CLIP
2 - BOLTS (2)
3 - BOLTS (2)
4 - BOLT (1)
KJDOORS - REAR 23 - 133
TRIM PANEL (Continued)

(3) Install the runout tube clip.
(4) Tighten the bolts to 9 N´m (80 in. lbs.) using
the sequence shown. (Fig. 14)
(5) Install the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - INSTALLATION)
WINDOW REGULATOR -
ELECTRIC
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOORS - REAR/DOOR GLASS - REMOVAL)
(2) Remove the bolts. (Fig. 15)
(3) Disconnect the runout tube clip and remove the
regulator.
(4) Disconnect the electrical connector.
INSTALLATION
(1) Connect the electrical connector.
(2) Loosely install the bolts onto the regulator
assembly.
(3) Install the regulator assembly.
(4) Tighten the bolts to 9 N´m (80 in. lbs.) using
the sequence shown. (Fig. 16)
(5) Install the glass. (Refer to 23 - BODY/DOORS -
REAR/GLASS RUN CHANNEL - INSTALLATION)
Fig. 14 REGULATOR TIGHTEN SEQUENCE
Fig. 15 WINDOW REGULATOR - REAR
1 - REGULATOR ASSEMBLY
2 - BOLTS (2)
3 - BOLTS (2)
4 - RUNOUT TUBE CLIP
5 - BOLT
Fig. 16 REGULATOR TIGHTENING SEQUENCE
23 - 134 DOORS - REARKJ
WINDOW REGULATOR - MANUAL (Continued)

SWING GATE
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL............................135
INSTALLATION........................135
EXTERIOR HANDLE
REMOVAL............................136
INSTALLATION........................136
FLIP-UP GLASS
REMOVAL............................136
INSTALLATION........................136
FLIP-UP GLASS LATCH
REMOVAL............................136
INSTALLATION........................136
HINGE
REMOVAL............................137
INSTALLATION........................137
LATCH
REMOVAL............................137
INSTALLATION........................137
LATCH STRIKER
REMOVAL............................137INSTALLATION........................137
LOCK CYLINDER
REMOVAL............................137
INSTALLATION........................138
SWING GATE
REMOVAL............................138
INSTALLATION........................138
TRIM PANEL
REMOVAL............................138
INSTALLATION........................138
LATCH - ACCESS PANEL
DESCRIPTION........................139
REMOVAL............................139
INSTALLATION........................139
FLIP-UP GLASS SUPPORT CYLINDER
REMOVAL............................139
INSTALLATION........................139
CHECK STRAP
REMOVAL
(1) Remove the swing gate trim panel. (Refer to 23
- BODY/SWING GATE/TRIM PANEL - REMOVAL)
(2) Remove the quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL)
(3) Remove the bolts attaching the check strap to
the d-pillar. (Fig. 1)
(4) Peel back the waterdam.
(5) Remove the nuts and remove the check strap
from the swing gate.
INSTALLATION
(1) Install the check strap.
(2) Install the nuts and tighten to 10 N´m (89 in.
lbs.).
(3) Reposition the waterdam.
(4) Install the trim panel. (Refer to 23 - BODY/
SWING GATE/TRIM PANEL - INSTALLATION)
(5) Install the bolts attaching the check strap to
the d-pillar and tighten to 11 N´m (8 ft. lbs.).
(6) Install the quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION)Fig. 1 CHECK STRAP
1 - CHECK STRAP
2 - NUTS (2)
3 - BOLTS (2)
4 - D-PILLAR
KJSWING GATE 23 - 135