Tab 9 JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES.........162
PAINT CODE
DESCRIPTION........................162
BASE COAT/CLEAR COAT FINISH
DESCRIPTION........................162PAINT TOUCH-UP
DESCRIPTION........................163
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION........................163
PAINT
SPECIFICATIONS - PAINT CODES
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Black Clear Coat DX8
Bright Cactus Green
Pearl CoatAFM
Bright Silver Metallic
Clear CoatWS2
Dark Garnet Red Pearl
CoatXRV
Flame Red Clear Coat PR4
Patriot Blue Pearl Coat WB7
Salsa Red Pearl Coat WE5
Shale Green Metallic
Clear CoatXGR
Steel Blue Pearl Coat XBQ
Stone White Clear Coat SW1
Woodland Brown Satin
GlowYU2
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Taupe L5
Dark Slate Gray DV
Dark Slate Gray/Light
TaupeD2
Taupe/Light Taupe L2
ACCESSORY COLORS
PART COLOR DAIMLERCHRYSLER
CODE
Renegade
Roof
Rack/Light
BarDeep Gray ZSP
Sport
Fascia/Wheel
FlareDark Neutral
GrayHS5
PAINT CODE
DESCRIPTION
The paint code is identified on the Vehicle Safety
Certification Label which is located on the drivers
door shut face. The color names provided in the Paint
and Trim Code Description chart are the color names
used on most repair product containers.
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
The original equipment finish is a multi step pro-
cess that involves cleaning, applying electro de-posi-
tion (E-coat), anti-chip primer, base coat, and clear
coat steps.
On most vehicles a two-part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
23 - 162 PAINTKJ

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

STATIONARY GLASS
TABLE OF CONTENTS
page page
DOOR GLASS
REMOVAL............................172
INSTALLATION........................172
QUARTER WINDOW
REMOVAL............................172
INSTALLATION........................172WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS....173
REMOVAL............................173
INSTALLATION........................173
DOOR GLASS
REMOVAL
(1) Remove the rear door glass run channel. (Refer
to 23 - BODY/DOORS - REAR/GLASS RUN CHAN-
NEL - REMOVAL)
INSTALLATION
(1) Install the rear door glass run channel. (Refer
to 23 - BODY/DOORS - REAR/GLASS RUN CHAN-
NEL - INSTALLATION)
QUARTER WINDOW
REMOVAL
(1) Remove the headliner as necessary to gain
access to the glass seal from the inside. (Refer to 23 -
BODY/INTERIOR/HEADLINER - REMOVAL)
(2) Cut urethane bonding from around quarter
window glass using a suitable sharp cold knife. A
pneumatic cutting device can be used if available.
(3) Separate glass from vehicle.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or swing gate flip-up glass is
slammed before urethane is cured, water leaks can
result.
The window opening fence should be cleaned of old
urethane bonding material.
(1) Install the headliner as necessary. (Refer to 23
- BODY/INTERIOR/HEADLINER - INSTALLATION)
(2) Clean inside of glass with Mopar Glass Cleaner
and lint-free cloth.
(3) Apply PVC (vinyl) primer 25 mm (1 in.) wide
around edge of glass. Wipe with clean/dry lint-free
cloth.
(4) Apply fence primer around edge of fence. Allow
at least eighteen minutes drying time.
(5) Apply a 10 mm (0.4 in.) bead of urethane
around window vinyl border location.
(6)
Position glass into window opening and lock clips
into place.
23 - 172 STATIONARY GLASSKJ

WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
²URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
²DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
²BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
²VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
²SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
²ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR -
REMOVAL)
(2) Remove cowl cover. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL)(3) Remove screws attaching windshield side mold-
ing to A-pillar.
(4) Remove upper windshield molding.
(5) Cut urethane bonding from around windshield
using a suitable sharp cold knife. A pneumatic cut-
ting device can be used if available.
(6) Separate windshield from vehicle.
INSTALLATION
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
CAUTION: Open a window before installing wind-
shield. This will avoid pressurizing the passenger
compartment. If a door or swing gate flip-up glass
is slammed before urethane is cured, water leaks
can result.
The windshield fence should be cleaned of old ure-
thane bonding material. Support spacers should be
cleaned and properly installed on weld studs or
repair screws at bottom of windshield opening.
(1) Place replacement windshield into windshield
opening. Position glass in the center of the opening
against the support spacers. Mark the glass at the
support spacers with a grease pencil or masking tape
and ink pen to use as a reference for installation.
Remove replacement windshield from windshield
opening.
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart.
(3) Clean inside of windshield with Mopar Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around edge of windshield. Wipe with clean/dry lint-
free cloth.
(5) Apply black-out primer 15 mm (.75 in.) wide on
top and sides of windshield and 25 mm (1 in.) on bot-
tom of windshield. Allow at least three minutes dry-
ing time.
(6) Position windshield spacers on lower fence
above support spacers at the edge of the windshield
opening.
(7) Align the dot on the upper molding to the tick
mark in the center of the glass and install upper
molding onto windshield.
(8) Apply a 10 mm (0.4 in.) bead of urethane
around perimeter of windshield along the inside of
the moldings. Apply two beads along the bottom
edge.
KJSTATIONARY GLASS 23 - 173

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................175
DIAGNOSIS AND TESTING
WATER DRAINAGE AND WIND NOISE
DIAGNOSIS.........................176
DIAGNOSTIC PROCEDURES...........176
GLASS PANEL
REMOVAL............................178
INSTALLATION........................178
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 178
GLASS PANEL SEAL
REMOVAL............................178
INSTALLATION........................178
SUNSHADE
REMOVAL............................179
INSTALLATION........................179
GUIDE ASSEMBLY
REMOVAL............................179
INSTALLATION........................179
WIND DEFLECTOR
REMOVAL............................180INSTALLATION........................180
OPENING TRIM LACE
REMOVAL............................180
INSTALLATION........................180
DRAIN TUBE
REMOVAL............................180
INSTALLATION........................181
MODULE ASSEMBLY
REMOVAL............................181
INSTALLATION........................181
DRIVE MOTOR
REMOVAL............................182
INSTALLATION........................182
CONTROL MODULE
REMOVAL............................183
INSTALLATION........................183
CONTROL SWITCH
DESCRIPTION........................184
OPERATION..........................184
DIAGNOSIS AND TESTING...............184
REMOVAL............................184
INSTALLATION........................184
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sunroof features a power sliding glass panel
and a sunshade which can be manually positioned
anywhere along its travel, rearward of glass panel
front edge.
The sunroof is electrically operated from two
switches located on the windshield header, rearwardof the map lamp. To operate the sunroof the ignition
switch must be in either the Accessory or On/Run
position. One switch (vent) is a push button type and
opens the sunroof to the vent position only. The other
switch (open/close) is a rocker type for opening and
closing the sunroof. Pressing and releasing the open
button once the sunroof will express open and the
wind deflector will raise. If the button is pressed a
second time the sunroof will stop in that position.
Pressing and holding the close button will close the
sunroof. If the close button is released the sunroof
will stop in that position.
KJSUNROOF 23 - 175

GLASS PANEL
REMOVAL
(1) Slide sunshade rearward to the open position.
(2) Move the glass panel to the closed position.
(3) Remove the four glass panel screws (Fig. 1).
(4) Lift off glass panel and remove from vehicle.
INSTALLATION
(1) Position glass panel on to mechanism lift arm.
(2) Start the four attaching screws.
(3) Center glass in opening by running a business
card around the glass.
(4) Adjust glass panel. (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - ADJUSTMENTS)
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT
(1) Move the sunshade rearward to the open posi-
tion.
(2) Move the sunroof glass panel to the fully closed
position.
(3) Adjust the glass one corner at a time.
(a) Loosen four glass screws (Fig. 2).
(b) Lift glass assembly and align the top of the
glass panel to the top of the roof panel.
(c) Tighten screw to 3.5 N´m (31 in. lbs.).
(d) Repeat steps a. and b. for each corner of the
glass panel.
(e) When properly adjusted, the front of the
glass panel is 1.75 mm (0.07 in.) to 2.75 mm (0.11
in.) lower than the roof surface and the rear edgeof the glass panel is 1.75mm (0.07 in.) to .75 mm
(0.03 in.) lower than the roof surface.
NOTE: Glass assembly seal is 2.5mm (0.1 in) higher
than the glass panel. Measure at 300mm (11.8 in)
outboard of the centerline of the vehicle.
(4) Verify sunroof operation and alignment. Check
fit and re-adjust as necessary.
GLASS PANEL SEAL
REMOVAL
(1) Remove sunroof glass panel. (Refer to 23 -
BODY/SUNROOF/GLASS PANEL - REMOVAL)
(2) Place glass panel on clean work area with the
top side up. Support the glass assembly from under-
side to avoid bending or otherwise damaging the
mounting tabs.
(3) Grasp the seal and pull seal away from the
glass panel. The seal is a one piece seal.
INSTALLATION
NOTE: Always position seal seam on center of the
passenger side of glass panel.
(1) Place seal into position.
(2) Install seal on glass. Using care working the
seal around the glass, being careful not to over
stretch the seal while installing.
(3) Install the glass panel. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - INSTALLATION)
Fig. 1 GLASS PANEL
1 - SCREWS
2 - GLASS PANEL
3 - MODULE ASSEMBLYFig. 2 GLASS PANEL
1 - SCREWS
2 - GLASS PANEL
3 - MODULE ASSEMBLY
23 - 178 SUNROOFKJ

CONTROL SWITCH
DESCRIPTION
Vehicles equipped with a power sunroof utilize an
sunroof control switch. On this model, the sunroof
control switch is located in the overhead console, in
between the two reading lamps. The switch is
mounted in the overhead console with four plastic
retaining tabs, molded into the switch housing.
This switch incorporates four selections of opera-
tion open, auto open, close and vent. The individual
switches in the sunroof control switch unit cannot be
repaired. If one switch is damaged or faulty, the
entire sunroof control switch unit must be replaced.
OPERATION
With the operation of the sunroof control switch,
voltage is directed to the sunroof motor, through the
switch contacts or control module. If the control
switch is depressed and held depressed the voltage
signal is controlled manually through the switch con-
tacts, so when the switch is released the sunroof
stops.
Refer to the owners manual for more information
on the operation of the sunroof switch and system.
DIAGNOSIS AND TESTING
The following test will determine if the sunroof
control switch is operating properly.
(1) Remove the overhead console from the head-
liner (Refer to 8 - ELECTRICAL/OVERHEAD CON-
SOLE - REMOVAL).
(2) Remove the sunroof control switch from the
overhead console (Refer to 23 - BODY/SUNROOF/
CONTROL SWITCH - REMOVAL).
(3) Using an ohmmeter, test the switch terminals
for proper continuity using the table below. If any ofthe terminals do not show proper continuity, replace
the sunroof control switch.
SWITCH POSITION
(DEPRESSED)CONTINUITY BETWEEN
TERMINALS
VENT (V) 3, 4
OPEN (AUTO) 1, 4
CLOSE 2, 4
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the overhead console from the head-
liner (Refer to 8 - ELECTRICAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Disconnect the sunroof control switch electrical
connector. Depress the connector retaining tab and
pull the connector straight out.
(4) To remove the switch from the overhead con-
sole, push on the back of the switch until it comes
free from the overhead console.
INSTALLATION
(1) Install the switch in the overhead console
assembly. Be certain the switch is securely snapped
in place.
(2) Connect the sunroof control switch electrical
connector. Be certain the switch connector is securely
snapped in place.
(3) Install the overhead console (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION).
(4) Connect the negative battery cable.
23 - 184 SUNROOFKJ

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR SEAL
REMOVAL............................185
INSTALLATION........................185
COWL WEATHERSTRIP
REMOVAL............................185
INSTALLATION........................185
DOOR PRIMARY WEATHERSTRIP
REMOVAL............................185
INSTALLATION........................185
DOOR LOWER WEATHERSTRIP
REMOVAL............................186
INSTALLATION........................186
FRONT DOOR OUTER BELT MOLDING
REMOVAL............................186
INSTALLATION........................186
SWING GATE BELTLINE WEATHERSTRIP
REMOVAL............................186
INSTALLATION........................186
SWING GATE OPENING WEATHERSTRIP
REMOVAL............................186INSTALLATION........................186
REAR DOOR OUTER BELT MOLDING
REMOVAL............................186
INSTALLATION........................186
SIDE RAIL WEATHERSTRIP/RETAINER
REMOVAL............................186
INSTALLATION........................186
WINDSHIELD A-PILLAR WEATHERSTRIP/
RETAINER
REMOVAL............................186
INSTALLATION........................187
COWL/PLENUM SEAL
REMOVAL............................187
INSTALLATION........................187
COWL/PLENUM WINDOW BAFFLE SEAL
REMOVAL............................187
INSTALLATION........................187
A-PILLAR SEAL
REMOVAL
(1) Open the doors and peal the seal away from
the a-pillar/windshield and the side rail weather
strip flanges.
INSTALLATION
(1) Position the a-pillar seal over the windshield/a-
pillar and the side rail weatherstrip flanges and seat
fully.
COWL WEATHERSTRIP
REMOVAL
(1) Open the hood and peal the cowl seal from the
cowl panel and cowl flange.
INSTALLATION
(1) Position the weatherstrip over the cowl flange
and the cowl grille and seat fully.
DOOR PRIMARY
WEATHERSTRIP
REMOVAL
(1) Remove the lower b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
REMOVAL)
(2) Peal seal off of the door opening flange.
INSTALLATION
(1) Position the seal to the bottom of the door
opening, with bulb facing outboard, starting the
installation at the center of the lower flange. Press
the seal onto the sill flange and work around the
perimeter of the door opening until fully seated.
Work in one direction, smoothing the seal to avoid
puckers or wrinkles.
(2) Install the lower b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR LOWER TRIM -
INSTALLATION)
(3) When installing a new weatherstrip on the
front door opening, remove the tear strip starting at
the splice and moving around the front of the door to
the back of the opening.
KJWEATHERSTRIP/SEALS 23 - 185

(4) When installing a new weatherstrip on the rear
door opening, remove the tear strip starting at the
splice and moving around the back of the door to the
front of the opening.
DOOR LOWER WEATHERSTRIP
REMOVAL
(1) Carefully disengage the push pin fasteners and
remove the seal.
INSTALLATION
(1) Position the seal and seat the push pin fasten-
ers.
FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Lower the window.
(2) Pull the outer belt molding off of the door
flange starting at the rear and moving forward.
INSTALLATION
(1) Press the belt molding onto the outer door win-
dow flange starting at the rear and working forward.
SWING GATE BELTLINE
WEATHERSTRIP
REMOVAL
(1) Remove the swing gate trim panel. (Refer to 23
- BODY/SWING GATE/TRIM PANEL - REMOVAL)
(2) Pull seal away from the corner tabs and
remove from the swing gate flange.
INSTALLATION
(1) Install the seal over the swing gate flange and
seat the corner tabs.
(2) Install the swing gate trim panel. (Refer to 23 -
BODY/SWING GATE/TRIM PANEL - INSTALLA-
TION)
SWING GATE OPENING
WEATHERSTRIP
REMOVAL
(1) Open the swing gate and peal seal off of the
gate opening flange.
INSTALLATION
(1) Position the seal to the bottom of the gate
opening starting the installation at the center of the
flange. Press the seal onto the sill flange and work
around the perimeter of the door opening until fully
seated. Work in one direction, smoothing the seal to
avoid puckers or wrinkles.
REAR DOOR OUTER BELT
MOLDING
REMOVAL
(1) Lower the window.
(2) Pull the outer belt molding off of the door
flange starting at the rear and moving forward.
INSTALLATION
(1) Press the belt molding onto the outer door win-
dow flange starting at the front and working back.
SIDE RAIL WEATHERSTRIP/
RETAINER
REMOVAL
(1) Remove the windshield weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/
WINDSHIELD A-PILLAR WEATHERSTRIP/RE-
TAINER - REMOVAL)
(2) Remove the two screws.
(3) Using a trim stick C-4755 or equivalent,
release the push in fasteners and remove the weath-
erstrip.
INSTALLATION
(1) Position the weatherstrip and seat the push in
fasteners.
(2) Install the two screws.
(3) Install the windshield weatherstrip. (Refer to
23 - BODY/WEATHERSTRIP/SEALS/WINDSHIELD
A-PILLAR WEATHERSTRIP/RETAINER - INSTAL-
LATION)
WINDSHIELD A-PILLAR
WEATHERSTRIP/RETAINER
REMOVAL
(1) Open the doors and peal the a-pillar seal away
from the a-pillar/windshield and the side rail
weather strip flanges.
(2) Remove the seven screws and remove the
weatherstrip.
23 - 186 WEATHERSTRIP/SEALSKJ
DOOR PRIMARY WEATHERSTRIP (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS.......................1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT........................2
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT........................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................2DIAGNOSIS AND TESTING - HEATER
PERFORMANCE.......................6
DIAGNOSIS AND TESTING - VACUUM
SYSTEM.............................6
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................9
SPECIFICATIONS
A/C APPLICATION TABLE................9
SPECIFICATIONS.....................10
CONTROLS.............................11
DISTRIBUTION..........................29
PLUMBING.............................38
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel. On heater-only systems, the evaporator coil is
omitted from the housing.
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the HVAC
system, the engine cooling system must be properly
maintained. The use of a bug screen is not recom-
mended. Any obstructions in front of the radiator or
condenser will reduce the performance of the air con-
ditioning and engine cooling systems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Engine Cooling for
more information before the opening of, or attempt-
ing any service to the engine cooling system.
Fig. 1 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
4- BLOWER MOTOR HOUSING
5- EVAPORATOR (A/C ONLY)
6- LOWER HVAC CASE ASSEMBLY
KJHEATING & AIR CONDITIONING 24 - 1