Body JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

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

EXTERIOR HANDLE
REMOVAL
(1) Remove the trim panel and waterdam. (Refer
to 23 - BODY/SWING GATE/TRIM PANEL -
REMOVAL)
(2) Disconnect the lock switch and flip-up glass
release electrical connectors.
(3) Unclip the threaded clips and disconnect the
actuator rods. (Fig. 2)
(4) Remove the screws.
(5) Remove the nuts and remove the handle.
INSTALLATION
(1) Install the handle and hold tightly against the
gate and support bracket.
(2) Install the nuts and tighten to 6 N´m (55 in.
lbs.).
(3) Install the screws.
(4) Connect the actuator rods and electrical con-
nectors.
(5) Install the trim panel and waterdam. (Refer to
23 - BODY/SWING GATE/TRIM PANEL - INSTAL-
LATION)
FLIP-UP GLASS
REMOVAL
(1) Open the flip-up glass and disconnect the elec-
trical connectors.(2) Remove the support cylinders. (Refer to 23 -
BODY/SWING GATE/FLIP-UP GLASS SUPPORT
CYLINDER - REMOVAL)
(3) Open the glass to the full travel with the sup-
port cylinders off.
(4) Remove the bolts and remove the glass. (Fig. 3)
INSTALLATION
(1) Install the flip-up glass and install the hinge
bolts.
(2) Install the support cylinders. (Refer to 23 -
BODY/SWING GATE/FLIP-UP GLASS SUPPORT
CYLINDER - INSTALLATION)
(3) Connect the electrical connectors.
(4) Adjust flip-up glass fit if necessary and tighten
the hinge bolts to 7 N´m (60 in. lbs.). (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
FLIP-UP GLASS LATCH
REMOVAL
(1) Remove the trim panel. (Refer to 23 - BODY/
SWING GATE/TRIM PANEL - REMOVAL)
(2) Disconnect the electrical connectors. (Fig. 4)
(3) Using a trim stick C-4755 or equivalent, mark
the location of the latch assembly for installation.
(4) Remove the nuts and remove the latch assem-
bly.
INSTALLATION
(1) Install the latch assembly.
Fig. 2 EXTERIOR HANDLE
1 - LOCK CYLINDER SCREW
2 - LATCH ACTUATOR ROD CONNECTOR
3 - EXTERIOR HANDLE
4 - NUTS (2)
5 - SCREWS (2)
Fig. 3 FLIP-UP GLASS
1 - BOLTS (4)
2 - HINGE MOUNTING HOLES
3 - DEFROSTER WIRE HARNESS
4 - DEFROSTER ELECTRICAL CONNECTOR
5 - FLIPPER GLASS
23 - 136 SWING GATEKJ

(2) Install the nuts and tighten to 12 N´m (9 ft.
lbs.).
(3) Connect the electrical connectors.
(4) Install the trim panel. (Refer to 23 - BODY/
SWING GATE/TRIM PANEL - INSTALLATION)
(5) Adjust the latch to achieve the best glass fit.
(Refer to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECIFICATIONS)
HINGE
REMOVAL
(1) Remove the swing gate. (Refer to 23 - BODY/
SWING GATE/SWING GATE - REMOVAL)
(2) Remove the bolts and remove the hinges.
INSTALLATION
(1) Install the hinges.
(2) Install the bolts and tighten to 31 N´m (23 ft.
lbs.).
(3) Install the swing gate. (Refer to 23 - BODY/
SWING GATE/ SWING GATE - INSTALLATION)
LATCH
REMOVAL
(1) Remove the trim panel and waterdam. (Refer
to 23 - BODY/SWING GATE/TRIM PANEL -
REMOVAL)
(2) Disconnect the electrical connector and actua-
tor rod at the threaded clip. (Fig. 5)(3) Remove the screws and remove the latch.
INSTALLATION
(1) Connect the electrical connector and install the
latch.
(2) Install the screws and tighten to 11 N´m (8 ft.
lbs.).
(3) Connect the actuator rod.
(4) Install the trim panel and waterdam. (Refer to
23 - BODY/SWING GATE/TRIM PANEL - INSTAL-
LATION)
LATCH STRIKER
REMOVAL
(1) Open the gate and remove the screws attaching
the striker to the d-pillar.
INSTALLATION
(1) Install the striker and install the nuts.
(2) Tighten the nuts to 28 N´m (21 ft. lbs.).
(3) Adjust the swing gate as necessary. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
LOCK CYLINDER
REMOVAL
(1) Remove the exterior handle. (Refer to 23 -
BODY/SWING GATE/EXTERIOR HANDLE -
REMOVAL)
Fig. 4 FLIP-UP GLASS LATCH
1 - NUTS (2)
2 - ELECTRICAL CONNECTOR
3 - SWING GATE
4 - ELECTRICAL CONNECTOR
5 - FLIP-UP GLASS LATCHFig. 5 LATCH
1 - SWING GATE
2 - LATCH ASSEMBLY
3 - ELECTRICAL CONNECTOR
4 - SCREWS
KJSWING GATE 23 - 137
FLIP-UP GLASS LATCH (Continued)

(2) Remove the clip and remove the lock cylinder
switch.
(3) Remove the screw and remove the lock cylin-
der. (Fig. 6)
INSTALLATION
(1) Install the lock cylinder.
(2) Install the screw and tighten to 6 N´m (50 in.
lbs.).
(3) Install the lock cylinder switch and retaining
clip.
(4) Install the exterior handle. (Refer to 23 -
BODY/SWING GATE/EXTERIOR HANDLE -
INSTALLATION)
SWING GATE
REMOVAL
(1) Remove the spare tire. (Refer to 22 - TIRES/
WHEELS/TIRES/SPARE TIRE - REMOVAL)
(2) Remove the quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL)
(3) Support the swing gate with a suitable lifting
device.
(4) Disconnect the wire harness.(5) Disconnect the check strap from the d-pillar.
(Refer to 23 - BODY/SWING GATE/CHECK STRAP -
REMOVAL)
(6) Remove the bolts and remove the swing gate.
INSTALLATION
(1) Install the swing gate and install the bolts.
(2) Tighten the bolts to 31 N´m (23 ft. lbs.).
(3) Adjust the swing gate as needed adding 4 mm
on the right side to compensate for sag after the
spare tire is installed. (Refer to 23 - BODY/BODY
STRUCTURE/GAP AND FLUSH - SPECIFICA-
TIONS)
(4) Connect the wire harness electrical connector.
(5) Connect the check strap. (Refer to 23 - BODY/
SWING GATE/CHECK STRAP - INSTALLATION)
(6) Install the quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION)
(7) Install the spare tire. (Refer to 22 - TIRES/
WHEELS/TIRES/SPARE TIRE - INSTALLATION)
TRIM PANEL
REMOVAL
(1) Using a trim stick C-4755 or equivalent,
release the push pin fasteners. (Fig. 7)
(2) Lift trim panel up off of the upper trim panel
clips
INSTALLATION
(1) Position the trim panel and seat the upper
clips.
(2) Fully seat the lower trim panel clips
Fig. 6 LOCK CYLINDER
1 - SCREW
2 - LOCK CYLINDER
3 - EXTERIOR HANDLE
Fig. 7 SWING GATE TRIM PANEL
1 - TRIM PANEL
2 - UPPER TRIM PANEL CLIPS
3 - UPPER TRIM CLIP HOLES
4 - TRIM PANEL LOCATOR HOLES
5 - SWING GATE LOCATOR PINS
6 - PUSH IN FASTENERS
23 - 138 SWING GATEKJ
LOCK CYLINDER (Continued)

EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL............................140
INSTALLATION........................140
COWL GRILLE
REMOVAL............................140
INSTALLATION........................140
EXTERIOR NAME PLATES
REMOVAL............................140
INSTALLATION........................141
FRONT FENDER
REMOVAL............................141
INSTALLATION........................141
FUEL FILL DOOR/HOUSING
REMOVAL............................141
INSTALLATION........................141
GRILLE
REMOVAL............................142
INSTALLATION........................142
GRILLE OPENING REINFORCEMENT
REMOVAL............................142
INSTALLATION........................142FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL............................143
INSTALLATION........................143
LUGGAGE RACK
REMOVAL............................144
INSTALLATION........................144
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL............................144
INSTALLATION........................144
SIDE VIEW MIRROR
REMOVAL............................145
INSTALLATION........................145
FRONT WHEEL OPENING FLARE MOLDINGS
REMOVAL............................145
INSTALLATION........................145
REAR WHEEL OPENING FLARE MOLDINGS
REMOVAL............................145
INSTALLATION........................145
RADIATOR CROSSMEMBER
REMOVAL............................146
INSTALLATION........................146
BODY SIDE MOLDINGS
REMOVAL
(1) Using a trim stick C-4755 or equivalent,
remove and discard the molding from the outside of
the door.
INSTALLATION
(1) Thoroughly clean all residue from the body side
molding attachment area of the door.
(2) Wipe area clean with a 50% solution of water
and alcohol and wipe dry.
(3) Apply new body side molding using the locators
in the door and apply pressure of approximately 40
p.s.i. over the entire surface of the molding.
COWL GRILLE
REMOVAL
(1) Remove the hood seal.
(2) Remove the wiper arms. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(3) Remove the four plastic retainers and remove
the cowl grill.
INSTALLATION
(1) Position the cowl grill and engage the nine
clips to the bottom of the windshield.
(2) Install the five plastic retainers.
(3) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
(4) Install the hood seal.
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Apply a length of masking tape on the body,
parallel to the top edge of the nameplate to use as a
guide, if necessary.
(2) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun. Do not exceed 52ÉC
(120ÉF) when heating emblem.
(3) Using a trim stick C-4755 or equivalent, behind
the emblem to separate the adhesive backing from
the body.
23 - 140 EXTERIORKJ

(4) Clean adhesive residue from body with MOPAR
Super Clean solvent or equivalent.
INSTALLATION
(1) Remove protective cover from adhesive tape on
back of emblem.
(2) Position emblem properly on body.
(3) Press emblem firmly to body with palm of
hand.
(4) If temperature is below 21ÉC (70ÉF) warm
emblem with a heat lamp or gun to assure adhesion.
Do not exceed 52ÉC (120ÉF) when heating emblem.
FRONT FENDER
REMOVAL
(1) Remove the wheel opening splash shield. (Refer
to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(2) Remove the fascia assembly. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT FASCIA -
REMOVAL)
(3) Remove the fender support bracket bolts. (Fig.
1)
(4) Remove the bolts and remove the fender. (Fig.
2)
INSTALLATION
(1) Install the fender assembly and install the
bolts
(2) Install the fender support bracket and install
the bolts.(3) Align the fender with adjacent body parts and
tighten the bolts to 12 N´m (9 ft. lbs.). (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
(4) Install the fascia assembly. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT FASCIA -
INSTALLATION)
(5) Install the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - INSTALLATION)
FUEL FILL DOOR/HOUSING
REMOVAL
(1) Remove the fuel cap.
(2) Remove the three screws connecting the fuel
door/housing to the filler neck.
(3) Reach in through the opening and depress the
tabs at the upper and bottom right of the door/hous-
ing. (Fig. 3)
(4) Remove the fuel door/housing from the vehicle.
INSTALLATION
(1) Position the fuel filler door/housing into the
vehicle and fully seat the tabs.
Fig. 1 FENDER SUPPORT BRACKET
1 - FENDER BOLTS (2)
2 - FENDER
3 - FENDER SUPPORT BRACKET
4 - SUPPORT BRACKET BOLTS (2)
5 - U-NUTS (2)
Fig. 2 FRONT FENDER
1 - HYDRAFORM
2 - U-NUTS
3 - BOLTS (3)
4 - FENDER
5 - BOLTS (2)
6 - BOLTS (2)
KJEXTERIOR 23 - 141
EXTERIOR NAME PLATES (Continued)

(2) Install the three screws.
(3) Install the fuel cap.
GRILLE
REMOVAL
(1) Remove the upper screws. (Fig. 4)
(2) Roll the grille forward and disengage the two
grille hooks under the headlamp units.
(3) Lift the grille forward and up off of the location
tabs at the bottom and remove.
INSTALLATION
(1) Install the grille onto the locating tabs at the
bottom.
(2) Push the grille back and snap into the hooks in
the grille opening reinforcement.
(3) Check that the black welts at the outboard
ends of the grille have a uniform appearance relative
to the fender and install the screws.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Remove the grille. (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL)
(2) Remove the front fascia. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCIA -
REMOVAL)
(3) Disconnect the electrical connectors. (Fig. 5)
(4) Disconnect the rubber side flap push pin con-
nectors.
(5) Remove the seven bolts and remove the grille
opening reinforcement.
(6) Disconnect the headlamp units electrical con-
nectors.
(7) Remove the headlamp units. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL)
INSTALLATION
(1) Install the headlamp units. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(2) Connect the headlamp unit electrical connec-
tors.
(3) Install the grille opening reinforcement and
install the seven bolts.
(4) Connect the rubber side flap and install the
push pin connectors.
(5) Connect the electrical connectors. (Fig. 5)
(6) Install the front fascia. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION)
(7) Install the grille. (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION)
Fig. 3 FUEL FILL DOOR/HOUSING
1 - FUEL FILL DOOR
2 - HOUSING TABS
Fig. 4 GRILLE
1 - GRILLE OPENING REINFORCEMENT
2 - SCREWS (4)
3 - GRILLE CLIPS
23 - 142 EXTERIORKJ
FUEL FILL DOOR/HOUSING (Continued)