Window JEEP LIBERTY 2002 KJ / 1.G Repair Manual

(8) Check if the spring tang is within the tolerance
window (Fig. 103). If the spring tang is within the
tolerance window, the installation process is complete
and nothing further is required. If the spring tang is
not within the tolerance window, repeat Steps 5
through 7.
(9) Install timing belt front covers and bolts.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION)
(10) Install air conditioning/generator belt ten-
sioner and pulley. (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS -
INSTALLATION)
(11) Install crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION)
(12) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(13) Install drive belt splash shield.
(14) Install air cleaner housing, upper cover, and
clean air tube.
Fig. 101 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK NUT
5 - SETTING NOTCH
6 - SPRING TANG
Fig. 102 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 103 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
9s - 58 ENGINEKJ
TIMING BELT AND SPROCKET(S) (Continued)

REMOVAL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: removing fuel pump module access plate, or
using DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank
(Fig. 38), the tank cannot be drained conventionally
at the fill cap.
The quickest draining procedure involves removing
fuel pump module access plate.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel pump
module access plate must be removed for fuel drain-
ing. Refer to following procedures.Fuel tank removal will not be necessary for
fuel tank draining. Access for draining is from
rear cargo area.
(1) Open all windows in vehicle to allow for air
ventilation.
(2) Four cargo holdown clamps are located inside
the vehicle on the floor of the rear cargo area.
Remove the 2 rearward mounted clamps by drilling
out the clamp rivets.
(3) Fold carpeting forward to gain access to fuel
pump module access plate (Fig. 39).
(4) Remove 4 fuel pump module access plate nuts
(Fig. 39).
(5) While applying heat from a heat gun, carefully
pry up fuel pump module access plate. Take care not
to bend plate.
(6) Thoroughly clean area around top of pump
module to prevent contaminants from entering fuel
tank or fuel lines.
(7) Release fuel system pressure.
(8) Disconnect 2 fuel lines (Fig. 40) at fuel pump
module by pressing on tabs at side of fitting.
(9) Disconnect electrical connector (Fig. 40). Slide
red tab first to unlock, and push grey tab down for
removal.
(10) Disconnect ORVR hose (Fig. 40) at pump mod-
ule fitting.
Fig. 38 FUEL FILL CHECK VALVE
1 - ONE-WAY CHECK VALVE
2 - FUEL FILL FITTING
3 - SIDE OF FUEL TANK
Fig. 39 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
KJFUEL DELIVERY 14 - 25
FUEL TANK (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
23 - 2 BODYKJ
BODY (Continued)

DESCRIPTION FIGURE
FULL FLOOR PAN ASSEMBLY
FULL FLOOR PAN ASSEMBLIES ( 39 )
FLOOR PAN AND RAIL ASSEMBLY ADHESIVE LOCATIONS ( 40 )
FLOOR PAN AND RAIL ASSEMBLY WELD LOCATIONS ( 41 )
FLOOR PAN, BODY SIDE SILL, COWL SIDE PANEL AND CROSSMEMBERS ( 42 )
WHEELHOUSE ADHESIVE LOCATIONS ( 43 )
WHEELHOUSE WELD LOCATIONS ( 44 )
BODY SIDE PANELS AND SUB ASSEMBLIES
A-PILLAR AND HEADER MOUNTING REINFORCEMENTS ( 45 )
B-PILLAR REINFORCEMENTS ( 46 )
C-PILLAR AND SEAT BACK MOUNTING REINFORCEMENTS ( 47 )
D-PILLAR REINFORCEMENTS ( 48 )
TAIL LAMP MOUNTING PANEL AND GATE STRIKER REINFORCEMENT ( 49 )
TAIL LAMP MOUNTING PANEL AND TAIL LAMP EXTENSION ( 50 )
SWING GATE OPENING PANEL AND ROOF HEADER ( 51 )
BODY SIDE PANELS
BODY SIDE PANEL ASSEMBLY ( 52 )
BODY SIDE OUTER, INNER FENDER REINFORCEMENT AND FENDER ASSEMBLY ( 53 )
BODY SIDE OUTER AND INNER PANELS; A-PILLAR ( 54 )
LOWER INNER BODY SIDE PANELS AND UPPER A-PILLARS ( 55 )
BODY SIDE PANEL ASSEMBLIES AND B-PILLAR. ( 56 )
BODY SIDE PANEL ASSEMBLIES AND C-PILLAR REINFORCEMENT ( 57 )
QUARTER WINDOW OPENING; SEAT BACK ATTACH REINFORCEMENT; C-PILLAR
REINFORCEMENT(58)
BODY SIDE PANEL ASSEMBLIES AND OUTER REAR WHEELHOUSES ( 59 )
OUTER REAR WHEELHOUSE WELDS AND ADHESIVE LOCATIONS ( 60 )
D-PILLAR AND TAIL LAMP ASSEMBLY WELD AND ADHESIVE LOCATIONS ( 61 )
SWING GATE STRIKER REINFORCEMENT WELDS AND ADHESIVE LOCATIONS ( 62 )
REAR WHEELHOUSE WELDS AND TAIL LAMP ADHESIVE LOCATIONS ( 63 )
FENDER ASSEMBLIES
INNER FENDER REINFORCEMENT AND GUSSETS ( 64 )
INNER FENDER REINFORCEMENT, GUSSETS, PLENUM AND WHEELHOUSES ( 65 )
INNER FENDER REINFORCEMENT AND WHEELHOUSES ( 66 )
PLENUM ASSEMBLY AND INNER SIDE PANELS ( 67 )
ROOF PANEL ASSEMBLIES
ROOF PANEL ASSEMBLY ( 68 )
ROOF PANEL AND BODY SIDE WELD AND ADHESIVE LOCATIONS ( 69 )
ROOF PANEL AND BODY SIDE WELD AND ADHESIVE LOCATIONS - SUNROOF
EQUIPPED(70)
ROOF AND HEADER PANEL ASSEMBLY ( 71 )
KJBODY STRUCTURE 23 - 11
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

Fig. 58 QUARTER WINDOW OPENING
KJBODY STRUCTURE 23 - 67
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

DOOR - FRONT
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL............................121
INSTALLATION........................121
DOOR
REMOVAL............................122
INSTALLATION........................122
DOOR GLASS
REMOVAL............................122
INSTALLATION........................122
EXTERIOR HANDLE
REMOVAL............................123
INSTALLATION........................123
GLASS RUN CHANNEL
REMOVAL............................123
INSTALLATION........................123
HINGE
REMOVAL............................123
INSTALLATION........................123
LATCH
REMOVAL............................124
INSTALLATION........................124ADJUSTMENTS
ADJUSTMENT.......................124
LATCH STRIKER
REMOVAL............................124
INSTALLATION........................124
LOCK CYLINDER
REMOVAL............................125
INSTALLATION........................125
TRIM PANEL
REMOVAL............................125
INSTALLATION........................126
WATERDAM
REMOVAL............................126
INSTALLATION........................126
WINDOW REGULATOR - MANUAL
REMOVAL............................126
INSTALLATION........................126
WINDOW REGULATOR - ELECTRIC
REMOVAL............................126
INSTALLATION........................126
CHECK STRAP
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Remove screws attaching door check to A-pillar.
(3) Remove the two nuts and remove the door
check strap. (Fig. 1)
INSTALLATION
NOTE: Make sure the proper orientation of the
check strap is maintained using the ªRº and ªLº on
the top.
(1) Install the check strap through the speaker
hole.
(2) Install the nuts and tighten to 12 N´m (9 ft.
lbs.).
(3) Connect the strap to the A-pillar and tighten
the bolts to 12 N´m (9 ft. lbs.).
(4) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
Fig. 1 CHECK STRAP
1 - NUTS
2 - CHECK STRAP
3 - SPEAKER OPENING
KJDOOR - FRONT 23 - 121

DOOR
REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the A-pillar.
(2) Support the door with a suitable lifting device.
(3) Remove the bolts attaching the check strap to
the a-pillar.
NOTE: The epoxy washers should not be removed
from the hinge. If the washers are removed the door
may have to be re-adjusted.
(4) Remove the nuts attaching the door hinges to
the door. (Fig. 2)
INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the nuts and washers if they were
removed previously and tighten to 23 N´m (17 ft.
lbs.).
(3) Connect the door wire harness electrical con-
nector.
(4) Connect the check strap to the a-pillar and
install the bolts.
(5) Tighten the check strap bolts to 12 N´m (9 ft.
lbs.).(6) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS)
DOOR GLASS
REMOVAL
(1) Remove the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - REMOVAL)
(2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Raise the glass to the position shown and using
a long flat blade or hook type tool, disengage clips
attaching glass retainer to regulator lift plate. (Fig.
3)
(4) Disconnect the glass from the regulator lift
plate and re-install the clips.
(5) Rotate the top of the glass toward the front
and remove the glass from the window opening.
INSTALLATION
(1) Install the glass through the window opening
and align the mounting plate to the lift plate.
(2) Engage the glass to the regulator lift plate.
(3) Install the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - INSTALLATION)
(4) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
Fig. 2 HINGES
1 - NUTS (4)
2 - EPOXY WASHERS (2) (NOT REMOVABLE)
3 - HINGES
4 - DOOR
Fig. 3 DOOR GLASS/REGULATOR
1 - DOOR GLASS ATTACHMENT CLIP (2)
2 - DOOR OPENING
3 - REGULATOR LIFT PLATE
4 - DOOR GLASS
23 - 122 DOOR - FRONTKJ

EXTERIOR HANDLE
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Disconnect the lock switch electrical connector,
if equipped. (Fig. 4)
(3) Disconnect the handle rod at the handle and
the key cylinder rod at the latch.
(4) Remove the screws.
(5) Remove the nuts and remove the handle.
INSTALLATION
(1) Position the handle on the door and slide fully
toward the rear of the door.
(2) Install the nuts and tighten to 6 N´m (55 in.
lbs.).
(3) Install the screws and tighten to 6 N´m (55 in.
lbs.).
(4) Connect the handle rod at the handle and the
key cylinder rod at the latch.
(5) Connect the lock switch electrical connector, if
equipped.
(6) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
GLASS RUN CHANNEL
REMOVAL
(1) Position the window into the down position.
(2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)(3) Remove the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - REMOVAL)
(4) Remove the front and rear bolts. (Fig. 5)
(5) Peal the weatherstrip out of the door frame
and remove the run channel through the window
opening.
INSTALLATION
(1) Install the run channel through the window
opening and into the door frame.
(2) Install the front, rear bolts and tighten to 9
N´m (80 in. lbs.).
(3) Install the outer belt molding. (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FRONT DOOR
OUTER BELT MOLDING - INSTALLATION)
(4) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
hinge location and remove the bolts.
INSTALLATION
(1) Install the hinges and bolts.
(2) Tighten bolts to 28 N´m (21 ft. lbs.).
(3) Install the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - INSTALLATION)
Fig. 4 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - NUTS
3 - SCREWS
4 - ELECTRICAL CONNECTOR
Fig. 5 GLASS RUN CHANNEL
1 - WINDOW OPENING
2 - REAR BOLTS (2)
3 - GLASS RUN CHANNEL
4 - FRONT BOLTS (2)
KJDOOR - FRONT 23 - 123

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.
WATERDAM
REMOVAL
(1) Remove the trim panel. (Refer to 23 - BODY/
DOOR - FRONT/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/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Loosen the bolts. (Fig. 13)
(3) Disconnect the runout tube clip and remove the
regulator.
INSTALLATION
(1) Install the regulator assembly.
(2) Tighten the bolts to 9 N´m (80 in. lbs.) using
the sequence shown. (Fig. 14)
(3) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
WINDOW REGULATOR -
ELECTRIC
REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Loosen the bolts. (Fig. 15)
(3) Disconnect the runout tube clip.
(4) Disconnect the electrical connector and remove
the regulator.
INSTALLATION
(1) Install the regulator assembly.
(2) Connect the electrical connector.
Fig. 11 TRIM PANEL CONNECTIONS
1 - ELECTRICAL CONNECTORS
2 - ALIGNMENT PINS
3 - LATCH ACTUATOR ROD
4 - TRIM PANEL
Fig. 12 FRONT DOOR WATERDAM
1 - DOOR
2 - LOCK ACTUATOR ROD
3 - INSIDE HANDLE ACTUATOR ROD AND HOLE
4 - ELECTRICAL CONNECTOR
23 - 126 DOOR - FRONTKJ
TRIM PANEL (Continued)

(3) Tighten the bolts to 9 N´m (80 in. lbs.) using
the sequence shown. (Fig. 16)
(4) Connect the runout tube clip.(5) Install the glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
Fig. 13 FRONT DOOR REGULATOR - MANUAL
1 - BOLTS
2 - BOLTS
3 - RUNOUT TUBE
4 - RUNOUT TUBE CLIP
5 - BOLTS
Fig. 14 REGULATOR TIGHTENING SEQUENCE
Fig. 15 WINDOW REGULATOR - ELECTRIC
1 - BOLTS (3)
2 - BOLT
3 - BOLT
4 - RUNOUT TUBE CLIP
5 - BOLTS (2)
6 - REGULATOR ASSEMBLY
Fig. 16 REGULATOR TIGHTENING SEQUENCE
KJDOOR - FRONT 23 - 127
WINDOW REGULATOR - ELECTRIC (Continued)