ECU JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

(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)

RESERVOIR
REMOVAL
REMOVAL - 3.7L
(1) Remove the power steering pump. (Refer to 19
- STEERING/PUMP - REMOVAL).
(2) Secure the pump in a holding fixture.
(3) Remove the retaining clips by prying the lock
tab upwards and tap the retaining clips off the pump
body. (Fig. 12)
(4) Remove the reservoir from the pump body.
REMOVAL - 2.4L
(1) Siphon out as much power steering fluid as
possible.
(2) Remove the power steering hoses.(3) Remove the bolt securing the reservoir to the
mounting bracket. (Fig. 13)
(4) Remove the reservoir.
INSTALLATION
INSTALLATION - 3.7L
(1) Install the reservoir to the pump body.
(2) Install the retaining clips to the pump and res-
ervoir.
(3) Install the pump to the engine. (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(4) Refill the power steering fluid and check for
leaks (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE).
INSTALLATION - 2.4L
(1) Install the reservoir to the mounting bracket.
(2) Install and tighten the bolt to
(3) Install the hoses.
(4) Refill the power steering fluid and check for
leaks (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE). (Fig. 13)
Fig. 12 FLUID RESERVOIR
1 - FLUID RESERVOIR
2 - RETAINING CLIP
3 - PULLEY
4 - PUMP BODY
Fig. 13 FLUID RESERVOIR - 2.4L
19 - 24 PUMPKJ

DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 14).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 15).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 15).
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radial-ply tires are sensitive to force impulses
caused by improper mounting, vibration, wheel
defects, or possibly tire imbalance.
To find out if tires are causing the noise or vibra-
tion, drive the vehicle over a smooth road at varyingspeeds. Note the noise level during acceleration,
deceleration and slight left and right steering inputs.
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 16). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before removing the tire
from the wheel. Use lubrication such as a mild soap
solution when dismounting or mounting tire. Use
tools free of burrs or sharp edges which could dam-
age the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and tighten to proper
torque specification.
CLEANING
Remove the protective coating on the tires before
delivery of a vehicle. This coating may cause deteri-
oration of the tires.
To remove the protective coating, apply warm
water and let it soak for a few minutes. Afterwards,
scrub the coating away with a soft bristle brush.
Steam cleaning may also be used to remove the coat-
ing.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Tire P215/75R16
Tire P235/70R16
Spare Tire P215/75D16
POLYSPARE ONLY ON
169
SPARE TIRE
REMOVAL
(1) Raise the license plate.
(2) Remove the two bolts securing the wheel cover
to the wheel.
(3) Remove the two lug nuts and the one wheel
lock (if equipped) securing the tire/wheel to the spare
tire carrier.
(4) Remove the spare tire.
Fig. 14 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
22 - 8 TIRES/WHEELSKJ
TIRES (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................3
STANDARD PROCEDURE - HEAT STAKING . . 3
SPECIFICATIONS........................4
SPECIAL TOOLS
BODY...............................5BODY STRUCTURE.......................6
HOOD................................119
DOOR - FRONT........................121
DOORS - REAR........................128
SWING GATE..........................135
EXTERIOR............................140
INSTRUMENT PANEL....................147
INTERIOR.............................156
PAINT................................162
SEATS...............................164
STATIONARY GLASS....................172
SUNROOF.............................175
WEATHERSTRIP/SEALS..................185
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
²USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL±BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DaimlerChrysler Corporation uses many different
types of push-in fasteners to secure the interior and
exterior trim to the body. Most of these fasteners can
be reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component being
removed. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
KJBODY 23 - 1

DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessivewear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger's clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker, and safety latch should be lubricated period-
ically.
(5) The door lock cylinders should be lubricated
twice each year (preferably autumn and spring).
²Spray a small amount of lock cylinder lubricant
directly into the lock cylinder.
²Apply a small amount to the key and insert it
into the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with
a clean cloth to avoid soiling of clothing.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
KJBODY 23 - 3
BODY (Continued)

SIDE VIEW MIRROR
REMOVAL
(1) Remove the trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connector. (Fig. 10)
(3) Remove the three nuts and remove the mirror
assembly.
INSTALLATION
(1) Install the mirror assembly.
(2) Install the three nuts and tighten to 7 N´m (65
in. lbs.).
(3) Connect the electrical connector.
(4) Install the trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
FRONT WHEEL OPENING
FLARE MOLDINGS
REMOVAL
(1) Remove the 10 rivets connecting the flare to
the splash shield, flare brackets, fascia and air dam.
(Fig. 11)
(2) Using a trim stick C-4755 or equivalent, sepa-
rate the clips attaching the molding to the fascia and
fender.
(3) Remove the flare molding.
INSTALLATION
(1) Position flare molding and seat clips into the
fascia.
(2) Seat the remaining clips into the fender.(3) Install ten new rivets securing the flare mold-
ing to the splash shield, flare brackets, fascia and air
dam.
REAR WHEEL OPENING FLARE
MOLDINGS
REMOVAL
(1) Open the rear door and remove the five rivets
from the inside surface of the door. (Fig. 12)
(2) Using a trim stick C-4755 or equivalent, sepa-
rate the clips attaching the molding to the door and
remove the molding.
(3) Remove the 5 rivets from the rear flare and
splash shield.
(4) Using a trim stick C-4755 or equivalent, sepa-
rate the clips attaching the molding to the body and
the rear fascia and remove the molding.
(5) Remove the two rivets and remove the flare
extension. (Fig. 13)
INSTALLATION
(1) Install the flare extension and install two new
rivets.
(2) Position the rear flare molding and seat the
clips attaching it to the body and the rear fascia.
(3) Install five new rivets attaching the flare to the
splash shield.
Fig. 10 SIDE VIEW MIRROR
1 - MIRROR ASSEMBLY
2 - NUTS (3)
3 - ELECTRICAL CONNECTOR
Fig. 11 FRONT WHEEL OPENING FLARE MOLDING
1 - FLARE MOLDING
2 - RIVETS (10)
KJEXTERIOR 23 - 145

(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)

INSTALLATION
(1) Position the trim panel and seat the retaining
clips.
(2) Install the seat belt turning loop. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT &
RETRACTOR - INSTALLATION)
(3) Install the b-pillar lower trim panel. (Refer to
23 - BODY/INTERIOR/B-PILLAR LOWER TRIM -
INSTALLATION)
CARPETS AND FLOOR MATS
REMOVAL
Front Carpet
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)
(3) Remove the rear seats. (Refer to 23 - BODY/
SEATS/SEAT - REAR - REMOVAL)
(4) Remove the cowl trim panels. (Refer to 23 -
BODY/INTERIOR/COWL TRIM COVER -
REMOVAL)
(5) Remove the b-pillar lower trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL)
(6) Remove the jack assembly.
(7) Remove the carpet.
Rear Cargo Carpet
(1) Remove the rivets attaching the cargo hooks to
the floor.
(2) Remove the carpet.
INSTALLATION
Front Carpet
(1) Install the carpet.
(2) Install the jack assembly.
(3) Install the b-pillar lower trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
INSTALLATION)
(4) Install the cowl trim panels. (Refer to 23 -
BODY/INTERIOR/COWL TRIM COVER - INSTAL-
LATION)
(5) Install the rear seats. (Refer to 23 - BODY/
SEATS/SEAT - REAR - INSTALLATION)
(6) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION)
(7) Install the front seats. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - INSTALLATION)
Rear Cargo Carpet
(1) Install the carpet and slide under the trim pan-
els.
(2) Install new rivets securing the carpet and
cargo hooks to the floor.
SHIFT BEZEL
REMOVAL
(1) Using a trim stick C-4755 or equivalent, pry
shift bezel out of the floor console.
INSTALLATION
(1) Position the shift bezel and seat the retaining
clips into the floor console.
FLOOR CONSOLE
REMOVAL
(1) Remove the shift bezel, if equipped. (Refer to
23 - BODY/INTERIOR/SHIFT BEZEL - REMOVAL)
(2) Set park brake lever in the up position.
(3) Using a trim stick C-4755 or equivalent, dis-
connect the manual trans shifter boot, if equipped.
(4) Using a trim stick C-4755 or equivalent, dis-
connect the transfer case shifter boot, if equipped.
(5) Remove the four bolts. (Fig. 3)
(6) Lift the console at the back and remove.
INSTALLATION
(1) Position the front of the console and lower the
rear over the shifter and brake levers.
(2) Install the bolts.
(3) Install the shift boots and seat the retainer
clips.
(4) Install the shift bezel. (Refer to 23 - BODY/IN-
TERIOR/SHIFT BEZEL - INSTALLATION)
FLOOR CONSOLE LID LATCH
REMOVAL
(1) Remove the screws and remove the lid.
(2) Remove the screws attaching the lid cover and
remove the latch.
INSTALLATION
(1) Install the latch and the lid cover.
(2) Install the screws attaching the lid cover.
(3) Install the console lid onto the console and
install the screws.
23 - 158 INTERIORKJ
B-PILLAR UPPER TRIM (Continued)

SEATS
TABLE OF CONTENTS
page page
HEADREST
REMOVAL............................164
INSTALLATION........................164
HEADREST SLEEVE
REMOVAL............................164
INSTALLATION........................164
SEAT - FRONT
REMOVAL............................165
INSTALLATION........................165
SEAT BACK - FRONT
REMOVAL............................166
INSTALLATION........................166
SEAT BACK RECLINER - FRONT
REMOVAL............................166
INSTALLATION........................166
SEAT BACK COVER - FRONT
REMOVAL............................166
INSTALLATION........................167
SEAT BACK CUSHION - FRONT
REMOVAL............................167
INSTALLATION........................167
SEAT CUSHION - FRONT
REMOVAL............................167
INSTALLATION........................167
SEAT CUSHION COVER - FRONT
REMOVAL............................167
INSTALLATION........................167
SEAT CUSHION SIDE SHIELDS
REMOVAL............................167
INSTALLATION........................167MANUAL SEAT RISER
REMOVAL............................167
INSTALLATION........................168
SEAT TRACK
REMOVAL............................168
INSTALLATION........................168
SEAT - REAR
REMOVAL............................168
INSTALLATION........................168
SEAT BACK - REAR
REMOVAL............................168
INSTALLATION........................168
SEAT BACK COVER - REAR
REMOVAL............................169
INSTALLATION........................169
SEAT BACK CUSHION - REAR
REMOVAL............................170
INSTALLATION........................170
FOLDING REAR SEAT BACK LATCH / LOCK
REMOVAL............................170
INSTALLATION........................170
REAR SEAT BACK LATCH STRIKER
REMOVAL............................170
INSTALLATION........................171
SEAT BACK FRAME - REAR
REMOVAL............................171
INSTALLATION........................171
SEAT CUSHION - REAR
REMOVAL............................171
INSTALLATION........................171
HEADREST
REMOVAL
(1) Depress head restraint release button and lift
head restraint to full up position.
(2) Using a small flat blade, depress tab on right
side head restraint release button and using your
hand, simultaneously press tab on left side head
restraint release button and pull head restraint up to
separate from seat back.
INSTALLATION
(1) Position head restraint in seat back, press tab
on left side head restraint release button and push
down head restraint to secure.
HEADREST SLEEVE
REMOVAL
(1) Remove the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - REMOVAL)
(2) Remove the headrest sleeve cover.
(3) Rotate head restraint sleeve 1/4 turn counter-
clockwise to release retaining tab.
(4) Pull sleeve from seat back frame.
INSTALLATION
(1) Position sleeve in seat back frame.
(2) Rotate head restraint sleeve 1/4 turn clockwise
to engage retaining tab.
(3) Install the headrest sleeve cover.
(4) Install the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - INSTALLATION)
23 - 164 SEATSKJ

(4) Test sunroof operation, adjust as necessary.
(5) Install headliner. (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION)
CONTROL MODULE
REMOVAL
(1) Remove the module assembly. (Refer to 23 -
BODY/SUNROOF/MODULE ASSEMBLY -
REMOVAL)
(2) Remove three motor assembly retaining screws
from bottom side of motor, and remove motor assem-
bly (Fig. 11).
(3) From top side of module assembly, remove one
attaching screw from electronics module. (Fig. 12)
(4) Remove old timing module.
INSTALLATION
(1) Check glass assembly position. Adjust to full
closed position. Insert pin into holes in lift arm
assembly to check position (Fig. 13).
(2) Set new electronic module in position on top
side of motor mounting bracket engaging drive cables
with pinion gear in electronics module.
(3) Install one screw to attach electronics module
to motor bracket. Tighten screw to 3 N´m (27 in. lbs.)
torque.
(4) Install motor assembly to motor bracket and
electronics module with three screws. Tighten screw
to 1.75 N´m (15.5 in. lbs.) torque.
(5) Remove the new module's timing pin and dis-
card. (Fig. 14)(6) Connect electrical connector to module assem-
bly wire harness. Secure any loose wires.
(7) Install module assembly. (Refer to 23 - BODY/
SUNROOF/MODULE ASSEMBLY - INSTALLA-
TION)
(8) Test operation, adjust as necessary. (Refer to 23
- BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS)
(9) Install opening trim lace. (Refer to 23 - BODY/
SUNROOF/OPENING TRIM LACE - INSTALLA-
TION)
Fig. 12 CONTROL MODULE
1 - MOTOR BRACKET
2 - CABLES
3 - SCREW
4 - CONTROL MODULE
Fig. 13 LIFT ARM POSITIONING
1 - GLASS BRACKET
2 - LIFT ARM
3 - ALIGNMENT PIN
Fig. 14 MODULE TIMING PIN
1 - CONTROL MODULE
2 - TIMING PIN
KJSUNROOF 23 - 183
DRIVE MOTOR (Continued)