wire JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

(1) Open the glove box.
(2) Remove the two striker screws and remove the
latch striker.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install the striker and install the two screws.
(2) Loosen the screws to adjust if necessary.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL)
(3) Remove the speakers.
(4) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)
(5) Remove the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL)
(6) Remove the four nuts and remove the center
support bracket. (Fig. 6)
(7) Remove the steering column. (Refer to 19 -
STEERING/COLUMN - REMOVAL)
(8) Remove the drivers side cowl trim cover. (Refer
to 23 - BODY/INTERIOR/COWL TRIM COVER -
REMOVAL)
(9) Disconnect the wire harness connector behind
the drivers side cowl trim cover.
(10) Disconnect the green and light blue wire har-
ness bulk connectors at the junction block. (Fig. 1)
(11) Disconnect the electrical connector at the
inner side of the pedal support bracket. (Fig. 2)
(12) Remove the two bolts at the front of the pedal
support bracket. (Fig. 2)
(13) Remove the two bolts from the bottom side of
the pedal support bracket. (Fig. 2)
Fig. 1 JUNCTION BLOCK CONNECTORS
1 - ELECTRICAL CONNECTOR
2 - ELECTRICAL CONNECTOR
3 - PEDAL SUPPORT BRACKET
4 - JUNCTION BLOCK
KJINSTRUMENT PANEL 23 - 149
GLOVE BOX LATCH STRIKER (Continued)

(14) Remove the two roll down bracket bolts at the
left cowl side panel. (Fig. 6)
(15) Remove the ground strap bolt and disconnect
the restraint module electrical connector. (Fig. 3)
(16) Remove the glove box. (Refer to 23 - BODY/
INSTRUMENT PANEL/GLOVE BOX - REMOVAL)
(17) Remove the two HVAC mounting bolts behind
the center trim. (Fig. 3)
(18) Remove the passenger side trim bezel. (Refer
to 23 - BODY/INSTRUMENT PANEL/IP PASSEN-
GER SIDE BEZEL - REMOVAL)(19) Remove the HVAC mounting bolt above the
glove box striker. (Fig. 4)
(20) Remove the HVAC bolt at the lower outside
corner of the glove box opening. (Fig. 5)
(21) Remove the passenger side cowl trim cover.
(Refer to 23 - BODY/INTERIOR/COWL TRIM
COVER - REMOVAL)
(22) Disconnect the blower resistor electrical con-
nector. (Fig. 5)
(23) Remove the two roll down bracket bolts at the
right cowl side panel.
Fig. 2 PEDAL SUPPORT BRACKET
1 - PEDAL SUPPORT BRACKET
2 - BOLTS
3 - BOLTS
4 - ELECTRICAL CONNECTOR
Fig. 3 HVAC BOLTS
1 - RESTRAINT MODULE
2 - HVAC BOLTS
3 - RADIO WIRE HARNESS
Fig. 4 HVAC UPPER BOLT
1 - BOLT
2 - GLOVE BOX STRIKER
3 - HVAC UNIT
Fig. 5 HVAC CONNECTIONS
1 - GLOVE BOX STRIKER
2 - BLOWER RESISTOR
3 - VACUUM CHECK VALVE
4 - BOLT
23 - 150 INSTRUMENT PANELKJ
INSTRUMENT PANEL ASSEMBLY (Continued)

(24) Disconnect the vacuum check valve and the
vacuum reservoir. (Fig. 5)
(25) Disconnect the blower motor electrical connec-
tor.
(26) Remove the four bolts at the top of the instru-
ment panel connecting to the cowl front panel.
(27) Roll the instrument panel rearward and
remove the wire harness from routing channel in the
rear.
(28) Disconnect the push pin fastener and position
aside the radio wire harness. Note the location of the
harness for installation.
(29) Remove the instrument panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THISIS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the instrument panel into the vehicle.
(2) Position the wire harness into the rear routing
channel and roll the instrument panel back against
the cowl.
(3) Position the radio wire harness and seat the
push pin fastener.
NOTE: Position the speaker wires through the
speaker openings.
(4) Install the four bolts at the top of the instru-
ment panel connecting to the cowl front panel and
tighten to 28 N´m (21 ft. lbs.).
(5) Connect the blower motor electrical connector.
(6) Connect the vacuum check valve and the vac-
uum reservoir.
(7) Connect the blower resister electrical connector.
NOTE: Do not push or pull bracket. Tighten at the
rest position.
Fig. 6 INSTRUMENT PANEL ASSEMBLY
1 - TOP BOLTS (4)
2 - CENTER SUPPORT BRACKET
3 - NUTS (4)4 - ROLL DOWN BOLTS (4)
5 - INSTRUMENT PANEL ASSEMBLY
KJINSTRUMENT PANEL 23 - 151
INSTRUMENT PANEL ASSEMBLY (Continued)

(8) Install the two roll down bracket bolts at the
right cowl side panel and tighten to 54 N´m (40 ft.
lbs.).
(9) Install the HVAC mounting bolt at the lower
outside corner of the glove box opening and tighten
to 6 N´m (55 in. lbs.).
(10) Install the HVAC mounting bolt above the
glove box striker.
(11) Install the passenger side trim bezel. (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL PASSENGER SIDE BEZEL - INSTALLA-
TION)
(12) Install the passenger side cowl trim cover.
(Refer to 23 - BODY/INTERIOR/COWL TRIM
COVER - INSTALLATION)
(13) Install the glove box. (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION)
NOTE: Do not push or pull bracket. Tighten at the
rest position.
(14) Install the two roll down bracket bolts at the
drivers cowl side panel and tighten to 54 N´m (40 ft.
lbs.).
(15) Install the two bolts at the bottom side of the
pedal support bracket.
(16) Install the two bolts at the front of the pedal
support bracket.
(17) Connect the electrical connector at the inner
side of the pedal support bracket.
(18) Connect the wiring harness electrical connec-
tors at the junction block.
(19) Connect the wire harness electrical connector
behind the drivers side cowl trim cover.
(20) Install the left cowl trim cover. (Refer to 23 -
BODY/INTERIOR/COWL TRIM COVER - INSTAL-
LATION)
(21) Install the steering column. (Refer to 19 -
STEERING/COLUMN - INSTALLATION)
(22) Install the two HVAC mounting bolts behind
the center trim.
(23) Install the ground strap and bolt and connect
the restraint module electrical connector.
(24) Install the center support bracket and hold it
tight against the instrument panel.
(25) Tighten the lower nuts to 23 N´m (17 ft. lbs.).
(26) Tighten the upper bracket nuts to 23 N´m (17
ft. lbs.).
(27) Install the radio. (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION)
(28) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION)
(29) Install the speakers.
(30) Install the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)(31) Reconnect the battery ground cable.
INSTRUMENT PANEL TOP
COVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM AND GRAB HANDLE -
REMOVAL)
(2) Using a trim stick C-4755 or equivalent,
release the attachment clips and remove the top
cover. (Fig. 7)
Fig. 7 INSTRUMENT PANEL COVERS
1 - SIDE COVER
2 - INSTRUMENT PANEL ASSEMBLY
3 - TOP COVER
23 - 152 INSTRUMENT PANELKJ
INSTRUMENT PANEL ASSEMBLY (Continued)

HEADLINER
REMOVAL
(1) Remove the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM AND GRAB HANDLE -
REMOVAL)
(2) Remove the visors. (Refer to 23 - BODY/INTE-
RIOR/SUN VISOR - REMOVAL)
(3) Remove the sun visor support. (Refer to 23 -
BODY/INTERIOR/SUN VISOR SUPPORT -
REMOVAL)
(4) Remove the overhead console. (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - REMOVAL)
(5) Cut rear washer hose at the mark about half-
way up the a-pillar.
(6) Remove the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
REMOVAL)
(7) Remove the assist handles. (Refer to 23 -
BODY/INTERIOR/ASSIST HANDLE - REMOVAL)
(8) Remove the quarter trim. (Refer to 23 - BODY/
INTERIOR/QUARTER TRIM PANEL - REMOVAL)
(9) Disconnect the electrical connector along the
left d-pillar and remove the ground wire.
(10) Remove the dome light in the rear.
(11) Remove the sunroof opening trim lace, if
equipped. (Refer to 23 - BODY/SUNROOF/OPENING
TRIM LACE - REMOVAL)(12) Remove the rear washer nozzle.
(13) Remove the headliner.
INSTALLATION
(1) Install the headliner.
(2) Install the assist handles. (Refer to 23 - BODY/
INTERIOR/ASSIST HANDLE - INSTALLATION)
(3) Install the visors. (Refer to 23 - BODY/INTERI-
OR/SUN VISOR - INSTALLATION)
(4) Install the visor supports. (Refer to 23 - BODY/
INTERIOR/SUN VISOR SUPPORT - INSTALLA-
TION)
(5) Install the overhead console. (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION)
(6) Connect the rear washer hose, previously cut,
with a hose junction.
(7) Install the a-pillar trim and grab handles.
(Refer to 23 - BODY/INTERIOR/A-PILLAR TRIM -
INSTALLATION)
(8) Install the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
INSTALLATION)
(9) Install the rear washer nozzle.
(10) Connect the electrical connector and ground
wire at the left d-pillar.
(11) Install the quarter trim panels. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION)
(12) Install the rear dome light.
(13) Install the sunroof opening trim lace, if
equipped. (Refer to 23 - BODY/SUNROOF/OPENING
TRIM LACE - INSTALLATION)
QUARTER TRIM PANEL
REMOVAL
(1) Using a trim stick C-4755 or equivalent,
remove the rear header trim.
(2) Using a trim stick C-4755 or equivalent,
remove the rear sill plate.
(3) Remove the hook pin type connector.
(4) Fold down the rear seat.
(5) Remove the seat belt anchor and pivot. (Refer
to 8 - ELECTRICAL/RESTRAINTS/SEAT BELT &
RETRACTOR - REMOVAL)
(6) Remove the belt access panel. (Fig. 4)
(7) Remove the storage cover.
(8) Disconnect the 12v power supply electrical con-
nector, if equipped.
INSTALLATION
(1) Position the 12v power supply electrical con-
nector, if equipped.
(2) Install the storage cover.
Fig. 3 FLOOR CONSOLE
1 - SHIFT BEZEL
2 - ACCESSORY CUP
3 - BOLTS (4)
4 - FLOOR CONSOLE
KJINTERIOR 23 - 159
FLOOR CONSOLE LID LATCH (Continued)

(4) Disconnect the drain hose from the sunroof
housing (Fig. 8).
(5) Drain any liquid from hose connection, if nec-
essary.
(6) Disconnect the grommet, attachment clips and
remove the drain tube.
INSTALLATION
FRONT DRAIN TUBES
(1) Connect the drain hose to the sunroof housing
and test drainage.
(2) Connect the body grommet and attachment
clips.
(3) Install the instrument panel top panel. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
(4) Install the headliner. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION)
(5) Install sunroof opening trim lace. (Refer to 23 -
BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION)
REAR DRAIN TUBES
(1) Connect the drain hose to the sunroof housing
and test drainage.
(2) Connect the body grommet and attachment
clips.
(3) Install the headliner.(4) Install sunroof opening trim lace.
MODULE ASSEMBLY
REMOVAL
(1) Move glass panel to the fully closed position.
(2) Disconnect and isolate the negative battery
cable.
(3) Remove sunroof opening trim lace.
(4) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(5) Disconnect wire harness push in fasteners and
electrical connector. (Fig. 9)
(6) Disconnect the drain tubes from sunroof hous-
ing.
(7) Loosen fasteners attaching sunroof module
assembly.
(8) With the aid of a helper, remove fasteners
attaching sunroof module assembly to roof panel
(Fig. 10).
INSTALLATION
(1) With the Glass panel in the fully closed posi-
tion.
(2) Raise rear end of sunroof module assembly and
guide into position and start fasteners.
(3) Tighten the fasteners to 9 N´m (80 in. lbs.).
(4) Connect the drain tubes.
Fig. 7 FRONT DRAIN TUBE
1 - TUBE
2 - CLIPS
3 - GROMMET
Fig. 8 REAR DRAIN TUBE
1 - GROMMET
2 - TUBE
3 - CLIPS
KJSUNROOF 23 - 181
DRAIN TUBE (Continued)

(5) Connect wire harness.
(6) Install the headliner. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION)
(7) Install the opening trim lace. (Refer to 23 -
BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION)
(8) Connect battery negative cable.
(9) Test sunroof operation, adjust as necessary.
(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS)
DRIVE MOTOR
REMOVAL
(1) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(2) Cut wire retaining tape being careful not to cut
wires.
(3) Disconnect the electrical connector (Fig. 11).
(4) Remove three motor assembly attaching screws
from bottom side of motor assembly and remove
motor assembly from the motor bracket.
INSTALLATION
(1) Place motor into position and install screws
attaching motor to bracket.
NOTE: Hold electronics module to motor bracket
when inserting motor shaft to avoid disengaging
drive cables.
(2) Connect electrical connector.
(3) Tape wires to drive cables to prevent rattles.
Fig. 9 WIRE HARNESS
1 - CLIPS
2 - ELECTRICAL CONNECTOR
3 - WIRE HARNESS
Fig. 10 MODULE ASSEMBLY
1 - U-NUTS
2 - DRIVE MOTOR
3 - BOLTS
4 - GLASS OPENING
5 - MODULE ASSEMBLY
Fig. 11 DRIVE MOTOR ASSEMBLY
1 - CONTROL MODULE
2 - SCREWS
3 - DRIVE MOTOR
4 - SCREW
5 - ELECTRICAL CONNECTOR
23 - 182 SUNROOFKJ
MODULE ASSEMBLY (Continued)

(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)

(1) Connect a tachometer a manifold gauge set or
A/C recycling/charging station.
(2) Set the A/C Heater mode control switch knob in
the Recirculation Mode position, the temperature
control knob in the full cool position, and the blower
motor switch knob in the highest speed position.
(3) Start the engine and hold the idle at 1,000 rpm
with the compressor clutch engaged.
(4) The engine should be at operating temperature.
The doors and windows must be closed.
(5) Insert a thermometer in the driver side center
A/C (panel) outlet. Operate the engine for five min-
utes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity. If the
clutch cycles, unplug the a/c low pressure switch wire
harness connector. (Fig. 2). Place a jumper wire
across the terminals of the a/c low pressure switch
wire harness connector.
(7) With the compressor clutch engaged, record the
discharge air temperature and the compressor dis-
charge pressure.
(8) Compare the discharge air temperature to the
Performance Temperature and Pressure chart. If the
discharge air temperature is high, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - SPECIFICATIONS -
CHARGE CAPACITY).
Performance Temperature and Pressure
Ambient Air
Temperature21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Air Temperature at
Center Panel Outlet7É C
(45É F)7É C
(45É F)13É C
(55É F)13É C
(55É F)18É C
(64É F)
Compressor Inlet
Pressure at Service
Port (low Side)138 to 207 kPa
(20 to 30 psi)172 to 241
kPa
(25 to 35 psi)207 to 276
kPa
(30 to 40 psi)241 to 310
kPa
(35 to 45 psi)276 to 345 kPa
(40 to 50 psi)
Condensor Out
Pressuree at Service
POrt (High Side)1034 to 1724
kPa
(150 to 250
psi)1379 to 2068
kPa
(200 to 300
psi)1724 to 2413
kPa
(250 to 350
psi)1999 to 2689
kPa
(290 to 390
psi)2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor discharge pressure to
the Performance Temperature and Pressure chart. If
the compressor discharge pressure is high, see the
Pressure Diagnosis chart.
Fig. 2 A/C LOW PRESSURE SWITCH - TYPICAL
1 - A/C LOW PRESSURE SWITCH
2 - ACCUMULATOR
KJHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)

(5) Connect the test set hose or probe to the open
end of the leaking circuit. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each connection is made. If OK, replace the faulty
disconnected component. If not OK, go to Step 6.
(6)
To locate a leak in a vacuum line, leave one end
of the line plugged and connect the test set hose or
probe to the other end of the line. Run your fingers
slowly along the line while watching the test set gauge.
The vacuum reading will fluctuate when your fingers
contact the source of the leak. To repair the vacuum
line, cut out the leaking section of the line. Then, insert
the loose ends of the line into a suitable length of 3 mil-
limeter (0.125 inch) inside diameter rubber hose.
STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Disconnect the battery negative cable and iso-
late it.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 5).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery negative cable, and test
affected systems.
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle KJ- Liberty
System R134a w/ fixed
orifice tube
Compressor Sanden PXF-18 SP-10 PAG oil
Freeze±up
ControlA/C low
pressure switchaccumulator
mounted
Low psi Control opens < 25 psi
- resets > 43
psi
High psi Control switch - opens
> 450-490 psi -
resets <
270-330 psidischarge line
Control Head manual type
Mode Door vacuum
Blend Door electric
Recirculation
Doorvacuum
Blower Motor hardwired to
control headresistor block
Cooling Fan viscous for
cooling, single
speed electric
for A/C
Clutch Electro-
mechanical
Control relay PCM
Draw 2 - 3.7 amps @
12V  0.5V @ 70É F
Gap 0.0169- 0.0319
DRB IIIT
Reads TPS, RPM, A/C
switch test
Actuators clutch and fan
relay
Fig. 5 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
KJHEATING & AIR CONDITIONING 24 - 9
HEATING & AIR CONDITIONING (Continued)