Body JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

(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)

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)

INSTALLATION
(1) Position the weatherstrip and install the seven
screws.
(2) Position the a-pillar seal over the windshield/a-
pillar and the side rail weatherstrip flanges and seat
fully.
COWL/PLENUM SEAL
REMOVAL
(1) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(2) Remove the seal from the plenum flange above
the air inlet duct.
INSTALLATION
NOTE: Seal should not be touching the plenum baf-
fle flange seal.
(1) Position the seal on the plenum flange and seat
fully.(2) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
COWL/PLENUM WINDOW
BAFFLE SEAL
REMOVAL
(1) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(2) Remove the seal from the window below the
cowl/plenum seal.
INSTALLATION
(1) Position the seal against the upper flange of
the inner plenum window below the cowl/plenum seal
and seat fully.
(2) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
KJWEATHERSTRIP/SEALS 23 - 187
WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER (Continued)

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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the center bezel from the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - REMOVAL).
(3) Release the vacuum harness from the A/C
Heater control.
(4) Remove the four screws that secure the A/C
Heater control to the instrument panel (Fig. 11).(5) Pull the A/C Heater control assembly away
from the instrument panel far enough to access the
connections on the back of the control.
(6) Unplug the wire harness connectors from the
back of the A/C Heater control (Fig. 12).
INSTALLATION
(1) Plug the two wire harness connectors and one
vacuum connector into the back of the A/C Heater
control.
(2) Position the A/C Heater control in the instru-
ment panel bezel and secure it with four screws.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Reinstall the center bezel onto the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - INSTALLA-
TION).
(4) Connect the battery negative cable.
A/C HIGH PRESSURE SWITCH
DESCRIPTION
The A/C high pressure switch controls both A/C
compressor clutch engagement/disengagement, and
Fig. 11 A/C HEATER CONTROL
1 - REAR WINDOW DEFOGGER SWITCH
2 - BLOWER SPEED CONTROL
3 - MODE SELECT CONTROL
4 - TEMPERATURE SELECT CONTROL
Fig. 12 A/C HEATER CONTROL HEAD (Rear View)
1 - A/C HEATER CONTROL HEAD
2 - A/C HEATER CONTROL HEAD LIGHT
3 - REAR WINDOW DEFOGGER SWITCH AND TEMPERATURE
BLEND DOOR- CONNECTOR B (12 PIN)
4 - A/C HEATER CONTROL HEAD LIGHT
5 - MODE SELECT CONTROL
6 - BLOWER SPEED CONTROL- CONNECTOR A (7 PIN)
7 - MOUNTING SCREWS (4)
KJCONTROLS 24 - 17
A/C HEATER CONTROL (Continued)

MODE DOOR ACTUATOR
REMOVAL
REMOVAL - PANEL DOOR ACTUATOR
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE 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 AN ACCIDENTAL AIRBAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
(1)Disconnect and isolate the battery negative cable.
(2) Remove the instrument panel assembly from
the vehicle(Refer to 23 - BODY/INSTRUMENT
PANEL - REMOVAL).
(3) Unplug the vacuum harness connector from the
defrost door actuator (Fig. 16).(4) Insert a trim stick or another suitable wide
flat-bladed tool into the latch hole on the HVAC
housing actuator mount. Gently pry the actuator
latch while pulling firmly outwards on the actuator
to remove the actuator from the mount.
(5) Rotate and tilt the vacuum actuator as
required to disengage the hole on the end of the
actuator link from the hooked pin on the end of the
defrost door lever.
(6) Remove the defrost door vacuum actuator from
the vehicle.
REMOVAL - FLOOR - DEFROST DOOR
ACTUATOR
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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel assembly from
the vehicle(Refer to 23 - BODY/INSTRUMENT
PANEL - REMOVAL).
(3) Unplug the vacuum harness connector from the
floor door actuator (Fig. 17).
(4) Insert a trim stick or another suitable wide
flat-bladed tool into the latch hole on the HVAC
housing actuator mount. Gently pry the actuator
latch while pulling firmly outwards on the actuator
to remove the actuator from the mount. (Fig. 18)
(5) Rotate and tilt the vacuum actuator as
required to disengage the hole on the end of the
actuator link from the hooked pin on the end of the
floor door lever.
(6) Remove the floor door vacuum actuator from
the vehicle.
Fig. 16 HVAC DOOR VACUUM ACTUATORS
1 - VACUUM LINE AND CONNECTOR
2 - PANEL DOOR ACTUATOR
3 - VACUUM LINE AND CONNECTOR
4 - FLOOR-DEFROST DOOR ACTUATOR
5 - HVAC ASSEMBLY
24 - 24 CONTROLSKJ

INSTALLATION
INSTALLATION - PANEL DOOR ACTUATOR
(1) Install the defrost door vacuum actuator by
snapping it into place, engage the hole on the end of
the actuator link with the hooked pin on the end of
the panel/demist door lever.
(2) Plug in the vacuum harness connector to the
defrost door actuator.
(3) Install the instrument panel assembly in the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Connect the battery negative cable.
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR
(1) Engage the hole on the end of the actuator
link to the hooked pin. Install the floor-defrost door
vacuum actuator to the HVAC assembly. on the end
of the floor door lever.
(2) Install the floor door vacuum actuator to the
HVAC assembly.
(3) Install the instrument panel assembly into the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Connect the battery negative cable.
Fig. 17 HVAC DOOR VACUUM ACTUATORS
1 - VACUUM LINE AND CONNECTOR
2 - PANEL DOOR ACTUATOR
3 - VACUUM LINE AND CONNECTOR
4 - FLOOR-DEFROST DOOR ACTUATOR
5 - HVAC ASSEMBLY
Fig. 18 VACUUM ACTUATOR REMOVE/INSTALL -
TYPICAL
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
KJCONTROLS 24 - 25
MODE DOOR ACTUATOR (Continued)