dimensions JEEP LIBERTY 2002 KJ / 1.G Owner's Manual

REAR FASCIA SUPPORT
REMOVAL
(1) Remove the rear fascia assembly. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL)
(2) Remove the six rivets and remove the fascia
support (Fig. 4).
INSTALLATION
(1) Install the fascia support onto the vehicle and
install six new rivets.
(2) Install the rear fascia assembly. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR FASCIA -
INSTALLATION)
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS
Frame dimensions are listed in metric scale. All
dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Using
screw or bottle jacks, adjust the vehicle PLP heights
to the specified dimension above a level work surface.
Vertical dimensions can be taken from the work sur-
face to the locations indicated were applicable.
NOTE: All measurements are in MM.
DIMENSION ILLUSTRATIONS
DESCRIPTION FIGURE
TOP VIEW ( 5 )
SIDE VIEW ( 6 )Fig. 4 REAR FASCIA SUPPORT
1 - RIVETS
2 - SUPPORT
KJFRAMES & BUMPERS 13 - 3

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

OPENING DIMENSIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
ENGINE COMPARTMENT ( 101 )
WINDSHIELD OPENING ( 102 )
BODY SIDE OPENINGS ( 103 )
SWING GATE OPENING ( 104 )
KJBODY STRUCTURE 23 - 111

Fig. 101 ENGINE COMPARTMENT
23 - 112 BODY STRUCTUREKJ
OPENING DIMENSIONS (Continued)

Fig. 102 WINDSHIELD OPENING
KJBODY STRUCTURE 23 - 113
OPENING DIMENSIONS (Continued)

Fig. 103 BODY SIDE OPENINGS
23 - 114 BODY STRUCTUREKJ
OPENING DIMENSIONS (Continued)

Fig. 104 SWING GATE OPENING
KJBODY STRUCTURE 23 - 115
OPENING DIMENSIONS (Continued)

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

CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) Install the original clutch shims on the com-
pressor shaft.
(7) Install the clutch plate. Install the shaft hex
nut and tighten to 15±20 N´m (11±15 ft. lbs.).
(8) Check the clutch air gap with a feeler gauge
(Fig. 9). If the air gap does not meet the specification,
add or subtract shims as required. The air gap spec-
ification is 0.41 to 0.79 millimeter (0.016 to 0.031
inch).NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use a 1.0, 0.50, and 0.13 mil-
limeter (0.040, 0.020, and 0.005 inch) shims from the
new clutch hardware package that is provided with
the new clutch.
(9) To complete the procedure, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The compressor clutch relay is a International
Standards Organization (ISO) micro-relay. The termi-
nal designations and functions are the same as a con-
ventional ISO relay. However, the micro-relay
terminal orientation (footprint) is different, the cur-
rent capacity is lower, and the relay case dimensions
are smaller than those of the conventional ISO relay.
The compressor clutch relay is located in the Power
Distribution Center (PDC) in the engine compart-
ment. Refer to the PDC label for relay identification
and location.
OPERATION
The compressor clutch relay is a electromechanical
device that switches battery current to the compres-
sor clutch coil when the Powertrain Control Module
(PCM) grounds the coil side of the relay. The PCM
responds to inputs from the A/C Heater mode control
switch, the A/C low pressure switch, and the A/C
high pressure switch. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR
CLUTCH RELAY - DIAGNOSIS AND TESTING)
The compressor clutch relay cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY
RELAY TEST
The compressor clutch relay (Fig. 10) is located in
the Power Distribution Center (PDC). Refer to the
PDC label for relay identification and location.
Remove the relay from the PDC to perform the fol-
lowing tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
Fig. 8 CLUTCH PULLEY INSTALL
1 - ROTOR BEARING ASSEMBLY
2 - INSTALLER
Fig. 9 CHECK CLUTCH AIR GAP
1 - FEELER GAUGE
KJCONTROLS 24 - 15
A/C COMPRESSOR CLUTCH (Continued)

DIFFERENTIAL - TRAC-LOK - CLEANING . . 3-109,
3-77
DIFFERENTIAL - TRAC-LOK -
DISASSEMBLY...................3-107,3-75
DIFFERENTIAL - TRAC-LOK -
INSPECTION....................3-109,3-77
DIFFERENTIAL CASE BEARINGS -
INSTALLATION...............3-110,3-44,3-79
DIFFERENTIAL CASE BEARINGS -
REMOVAL..................3-110,3-43,3-79
DIMENSIONS - SPECIFICATIONS, FRAME . . . 13-3
DIMENSIONS - SPECIFICATIONS,
OPENING..........................23-111
DIODE - INSTALLATION............8W-01-14
DIODE - REMOVAL................8W-01-14
DIODE REPLACEMENT - STANDARD
PROCEDURE.........................24-9
DISASSEMBLY - POWER DISTRIBUTION
CENTER DISASSEMBLY.............8W-97-7
DISASSEMBLY, 4C RETAINER/BULKHEAD . 21-122
DISASSEMBLY, DIAGNOSIS AND
TESTING...........................21-83
DISASSEMBLY, DIFFERENTIAL......3-105,3-41
DISASSEMBLY, DIFFERENTIAL -
TRAC-LOK......................3-107,3-75
DISASSEMBLY, DISASSEMBLY - POWER
DISTRIBUTION CENTER.............8W-97-7
DISASSEMBLY, DISC BRAKE CALIPERS....5-14
DISASSEMBLY, HVAC HOUSING.........24-34
DISASSEMBLY, INPUT CLUTCH
ASSEMBLY.........................21-135
DISASSEMBLY, INSTRUMENT CLUSTER....8J-9
DISASSEMBLY, LOW/REVERSE CLUTCH . . 21-145
DISASSEMBLY, MANUAL - NV1500........21-4
DISASSEMBLY, MANUAL - NV3550.......21-35
DISASSEMBLY, OIL PUMP...............9-65
DISASSEMBLY, OIL PUMP.............21-149
DISASSEMBLY, PLANETARY GEARTRAIN . 21-159
DISASSEMBLY, SINGLE CARDAN
UNIVERSAL JOINTS....................3-8
DISASSEMBLY, TRANSFER CASE -
NV231............................21-182
DISASSEMBLY, TRANSFER CASE -
NV242............................21-218
DISASSEMBLY, VALVE BODY...........21-173
DISASSEMBLY, WHEEL CYLINDERS.......5-28
DISC - INSTALLATION, CLUTCH...........6-6
DISC - REMOVAL, CLUTCH...............6-6
DISC BRAKE CALIPER ADAPTER -
INSTALLATION........................5-18
DISC BRAKE CALIPER ADAPTER -
REMOVAL...........................5-18
DISC BRAKE CALIPERS - ASSEMBLY......5-16
DISC BRAKE CALIPERS - CLEANING......5-16
DISC BRAKE CALIPERS - DESCRIPTION....5-13
DISC BRAKE CALIPERS - DISASSEMBLY . . . 5-14
DISC BRAKE CALIPERS - INSPECTION.....5-16
DISC BRAKE CALIPERS - INSTALLATION . . . 5-17
DISC BRAKE CALIPERS - OPERATION.....5-14
DISC BRAKE CALIPERS - REMOVAL.......5-14
DISC BRAKE ROTOR - DIAGNOSIS AND
TESTING............................5-18
DISC BRAKE ROTOR - STANDARD
PROCEDURE.........................5-19
DISCHARGE (ESD) SENSITIVE DEVICES -
STANDARD PROCEDURE,
ELECTROSTATIC...................8W-01-8
DISCHARGE LINE - INSTALLATION, A/C . . . 24-47
DISCHARGE LINE - REMOVAL, A/C.......24-46
DISPLAY TEST MODE - DESCRIPTION,
STATE ..............................25-2
DISTRIBUTION - DESCRIPTION, POWER . 8W-97-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1
DISTRIBUTION CENTER - DESCRIPTION,
POWER..........................8W-97-6
DISTRIBUTION CENTER - OPERATION,
POWER..........................8W-97-7
DISTRIBUTION CENTER - REMOVAL,
POWER..........................8W-97-7
DISTRIBUTION CENTER ASSEMBLY,
ASSEMBLY - POWER
..............8W-97-10
DISTRIBUTION CENTER DISASSEMBLY,
DISASSEMBLY - POWER
............8W-97-7
DISTRIBUTION SYSTEMS, SPECIAL
TOOLS - POWER
...................8W-97-2
DOO - INSTALLATION, FLOOR -
DEFROST
...........................24-37
DOOR - INSTALLATION
.........23-122,23-129DOOR - INSTALLATION, BLEND.........24-35
DOOR - INSTALLATION, PANEL..........24-36
DOOR - INSTALLATION, PASSENGER
AIRBAG............................8O-30
DOOR - INSTALLATION, RECIRC.........24-37
DOOR - REMOVAL.............23-122,23-129
DOOR - REMOVAL, BLEND.............24-35
DOOR - REMOVAL, DEFROST...........24-35
DOOR - REMOVAL, FLOOR - DEFROST....24-36
DOOR - REMOVAL, PASSENGER AIRBAG . . 8O-29
DOOR - REMOVAL, RECIRC............24-37
DOOR ACTUATOR - INSTALLATION,
BLEND.............................24-20
DOOR ACTUATOR - INSTALLATION,
FLOOR - DEFROST...................24-25
DOOR ACTUATOR - INSTALLATION,
PANEL.............................24-25
DOOR ACTUATOR - INSTALLATION,
RECIRCULATION.....................24-26
DOOR ACTUATOR - REMOVAL, BLEND....24-20
DOOR ACTUATOR - REMOVAL, FLOOR -
DEFROST...........................24-24
DOOR ACTUATOR - REMOVAL, PANEL....24-24
DOOR ACTUATOR - REMOVAL,
RECIRCULATION.....................24-26
DOOR AJAR INDICATOR - DESCRIPTION . . 8J-17
DOOR AJAR INDICATOR - OPERATION....8J-17
DOOR AJAR SWITCH - DESCRIPTION....8L-77
DOOR AJAR SWITCH - OPERATION........8L-77
DOOR CYLINDER LOCK SWITCH -
DESCRIPTION........................8Q-9
DOOR CYLINDER LOCK SWITCH -
DIAGNOSIS AND TESTING.............8Q-10
DOOR CYLINDER LOCK SWITCH -
INSTALLATION......................8Q-10
DOOR CYLINDER LOCK SWITCH -
OPERATION.........................8Q-10
DOOR CYLINDER LOCK SWITCH -
REMOVAL..........................8Q-10
DOOR GLASS - INSTALLATION . . 23-122,23-129,
23-172
DOOR GLASS - REMOVAL......23-122,23-129,
23-172
DOOR LOCK / UNLOCK SWITCH -
INSTALLATION.......................8N-5
DOOR LOCK / UNLOCK SWITCH -
REMOVAL...........................8N-4
DOOR LOCK MOTOR - DESCRIPTION......8N-5
DOOR LOCK MOTOR - DIAGNOSIS AND
TESTING............................8N-5
DOOR LOCK MOTOR - OPERATION.......8N-5
DOOR LOCK RELAY - DESCRIPTION......8N-6
DOOR LOCK RELAY - DIAGNOSIS AND
TESTING............................8N-6
DOOR LOCK RELAY - INSTALLATION......8N-7
DOOR LOCK RELAY - OPERATION........8N-6
DOOR LOCK RELAY - REMOVAL.........8N-6
DOOR LOCK/UNLOCK SWITCH -
DIAGNOSIS AND TESTING..............8N-4
DOOR LOWER WEATHERSTRIP -
INSTALLATION......................23-186
DOOR LOWER WEATHERSTRIP -
REMOVAL.........................23-186
DOOR OUTER BELT MOLDING -
INSTALLATION, FRONT...............23-186
DOOR OUTER BELT MOLDING -
INSTALLATION, REAR................23-186
DOOR OUTER BELT MOLDING -
REMOVAL, FRONT...................23-186
DOOR OUTER BELT MOLDING -
REMOVAL, REAR....................23-186
DOOR PRIMARY WEATHERSTRIP -
INSTALLATION......................23-185
DOOR PRIMARY WEATHERSTRIP -
REMOVAL.........................23-185
DOOR SCUFF PLATE - INSTALLATION,
REAR.............................23-160
DOOR SCUFF PLATE - REMOVAL, REAR . . 23-160
DOOR SILL SCUFF PLATE -
INSTALLATION......................23-157
DOOR SILL SCUFF PLATE - REMOVAL
. . . 23-157
DOOR/HOUSING - INSTALLATION, FUEL
FILL
..............................23-141
DOOR/HOUSING - REMOVAL, FUEL FILL
. 23-141
DOUBLE INVERTED FLARING -
STANDARD PROCEDURE
.................5-8
DRAIN AND FILL - STANDARD
PROCEDURE, FLUID
...........21-208,21-246DRAIN TUBE - INSTALLATION..........23-181
DRAIN TUBE - REMOVAL.............23-180
DRAINAGE AND WIND NOISE
DIAGNOSIS, DIAGNOSIS AND TESTING
- WATER ..........................23-176
DRAINING COOLING SYSTEM 3.7L
ENGINE - STANDARD PROCEDURE........7-12
DRAW TEST - STANDARD PROCEDURE,
IGNITION-OFF.......................8F-14
DRIVE - DIAGNOSIS AND TESTING,
VISCOUS FAN........................7-28
DRIVE BELT - DIAGNOSIS AND TESTING,
SERPENTINE.........................7-15
DRIVE MOTOR - INSTALLATION........23-182
DRIVE MOTOR - REMOVAL............23-182
DRIVER AIRBAG - DESCRIPTION........8O-17
DRIVER AIRBAG - INSTALLATION.......8O-20
DRIVER AIRBAG - OPERATION..........8O-18
DRIVER AIRBAG - REMOVAL...........8O-19
DRIVER SEAT HEATER SWITCH -
DESCRIPTION.......................8G-11
DRIVER SEAT HEATER SWITCH -
INSTALLATION......................8G-13
DRIVER SEAT HEATER SWITCH -
OPERATION.........................8G-12
DRIVER SEAT HEATER SWITCH -
REMOVAL..........................8G-13
DRIVER SIDE BEZELS - INSTALLATION,
INSTRUMENT PANEL.................23-154
DRIVER SIDE BEZELS - REMOVAL,
INSTRUMENT PANEL.................23-153
DROP - STANDARD PROCEDURE,
TESTING FOR A VOLTAGE...........8W-01-10
DRUM - DIAGNOSIS AND TESTING,
BRAKE..............................5-27
DRUM BRAKE - ADJUSTMENT, REAR......5-12
DRUM BRAKE - DESCRIPTION, REAR.....5-10
DRUM BRAKE - OPERATION, REAR.......5-11
DRUM BRAKE SHOES - INSTALLATION....5-11
DRUM BRAKE SHOES - REMOVAL........5-11
DRUM MACHINING - STANDARD
PROCEDURES, BRAKE.................5-27
DUCT - INSTALLATION, DEFROST/
DEMISTER..........................24-32
DUCT - INSTALLATION, FLOOR..........24-32
DUCT - INSTALLATION, FLOOR CONSOLE . 24-31
DUCT - REMOVAL, FLOOR.............24-32
DUCT - REMOVAL, FLOOR CONSOLE.....24-31
DUCT/DEMISTER ADAPTOR - REMOVAL,
DEFROST...........................24-32
EFFECTS OF INCORRECT FLUID LEVEL -
DIAGNOSIS AND TESTING............21-125
ELECTRIC - DESCRIPTION, RADIATOR
FAN ................................7-26
ELECTRIC - INSTALLATION, RADIATOR
FAN ................................7-27
ELECTRIC - INSTALLATION, WINDOW
REGULATOR.................23-126,23-134
ELECTRIC - OPERATION, RADIATOR FAN . . . 7-26
ELECTRIC - REMOVAL, RADIATOR FAN....7-26
ELECTRIC - REMOVAL, WINDOW
REGULATOR.................23-126,23-134
ELECTRICAL - DESCRIPTION............5-34
ELECTRICAL - OPERATION..............5-34
ELECTRICAL TESTER - STANDARD
PROCEDURE, USING MIDTRONICS.......8F-15
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES - STANDARD
PROCEDURE......................8W-01-8
ELEMENT - DESCRIPTION, HEATED SEAT . 8G-13
ELEMENT - DIAGNOSIS AND TESTING,
HEATED SEAT .......................8G-13
ELEMENT - OPERATION, HEATED SEAT . . . 8G-13
EMISSION CONTROL INFORMATION
(VECI) LABEL - DESCRIPTION,
VEHICLE..........................Intro.-8
EMISSION CONTROL SYSTEM -
DESCRIPTION........................25-1
END - INSTALLATION, TIE ROD.........19-16
END - REMOVAL, TIE ROD.............19-16
END CAP - INSTALLATION, INSTRUMENT
PANEL
............................23-153
END CAP - REMOVAL, INSTRUMENT
PANEL
............................23-153
END REMOVAL TOOL, SPECIAL TOOLS -
OUTER TIE ROD
.....................19-15
ENGINE - 3.7L - DESCRIPTION
............9-3
ENGINE - DESCRIPTION, 3.7L
............7-21
8 INDEXKJ
Description Group-Page Description Group-Page Description Group-Page