interior JEEP LIBERTY 2002 KJ / 1.G Manual PDF

mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Check that the interior lighting switch on the
left (lighting) control stalk of the multi-function
switch is not in the dome lamp disable position. With
all four doors and the tailgate closed, open the rear
flip-up glass. The interior lamps should light. Close
the rear flip-up glass. Note whether the interior
lamps remain lighted. They should turn off after
about thirty seconds. If OK, go to Step 2. If not OK,
go to Step 9.
(2) Check the fused B(+) fuse (Fuse 17 - 15
ampere) in the Junction Block (JB). If OK, go to Step
3. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse.
(3) Check for battery voltage at the fused B(+) fuse
(Fuse 17 - 15 ampere) in the JB. If OK, go to Step 4.
If not OK, repair the open fused B(+) circuit between
the JB and the Power Distribution Center (PDC) as
required.
(4) Check the fused ignition switch output (run-
acc) fuse (Fuse 22 - 10 ampere) in the JB. If OK, go
to Step 5. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse.
(5) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run-acc) fuse (Fuse 22 - 10 ampere) in the
JB. If OK, turn the ignition switch to the Off position
and go to Step 6. If not OK, repair the open fused
ignition switch output (run-acc) circuit between the
JB and the ignition switch as required.
(6) Disconnect and isolate the battery negative
cable. Disconnect the instrument panel wire harness
connector for the multi-function switch (Connector
C-2) from the switch connector receptacle. Reconnect
the battery negative cable. Turn the ignition switchto the On position. Check for battery voltage at the
fused ignition switch output (run-acc) circuit cavity of
the instrument panel wire harness connector for the
multi-function switch (Connector C-2). If OK, go to
Step 7. If not OK, repair the open fused ignition
switch output (run-acc) circuit between the multi-
function switch and the JB as required.
(7) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Test the multi-function switch. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/MULTI-
FUNCTION SWITCH - DIAGNOSIS AND
TESTING). If the multi-function switch tests OK,
reconnect the instrument panel wire harness connec-
tors for the multi-function switch to the switch con-
nector receptacles and go to Step 8. If the multi-
function switch does not test OK, replace the faulty
switch.
(8) Remove the tailgate inner trim panel. Discon-
nect the tailgate wire harness connector for the rear
wiper module from the module connector receptacle.
Check for continuity between the ground circuit cav-
ity of the tailgate wire harness connector for the rear
wiper module and a good ground. There should be
continuity. If OK, go to Step 9. If not OK, repair the
open ground circuit to ground (G312) as required.
(9) Check for continuity between the flip-up glass
ajar switch sense circuit cavity of the tailgate wire
harness connector for the rear wiper module and a
good ground. There should be continuity with the
rear flip-up glass open, and no continuity with the
rear flip-up glass closed. If OK, go to Step 10. If not
OK, repair the open flip-up glass ajar circuit between
the rear wiper module and the flip-up glass ajar
switch as required.
(10) Reconnect the battery negative cable. Check
for battery voltage at the fused B(+) circuit cavity of
the tailgate wire harness connector for the rear wiper
module. If OK, go to Step 11. If not OK, repair the
open fused B(+) circuit between the rear wiper mod-
ule and the JB as required.
(11) Turn the ignition switch to the On position.
Turn the control ring on the right (wiper) control
stalk of the multi-function switch to the Delay posi-
tion. Check for battery voltage at the rear wiper
intermittent driver circuit cavity of the tailgate wire
harness connector for the rear wiper module. If OK,
go to Step 12. If not OK, repair the open rear wiper
intermittent driver circuit between the rear wiper
module and the multi-function switch as required.
(12) Turn the control ring on the right (wiper) con-
trol stalk of the multi-function switch to the On posi-
tion. Check for battery voltage at the rear wiper on
driver circuit cavity of the tailgate wire harness con-
nector for the rear wiper module. If OK, replace the
faulty rear wiper module. If not OK, repair the open
KJREAR WIPERS/WASHERS 8R - 31
REAR WIPERS/WASHERS (Continued)

headliner hose is glued to top of the headliner and
routed along the right roof side rail to the rear of the
vehicle. At the rear of the vehicle, the headliner hose
passes through a hole at the rear portion of the roof
rear inner header panel and is connected to the rear
check valve. From the rear check valve, there is a
short section of hose that connects the rear check
valve to the rear washer nozzle.
Washer hose is available for service only as roll
stock, which must then be cut to length. The head-
liner washer hose is integral to the headliner unit
and, if faulty or damaged, the headliner unit must be
replaced. However, the headliner hose is marked
with a white cut line on the A-pillar where the hose
should be cut and spliced with a plastic in-line con-
nector fitting to facilitate headliner removal without
the need to remove the instrument panel. (Refer to
23 - BODY/INTERIOR/HEADLINER - REMOVAL
AND INSTALLATION). The molded plastic washer
hose fittings cannot be repaired. If these fittings are
faulty or damaged, they must be replaced.
OPERATION
Washer fluid in the washer reservoir is pressurized
and fed by the washer pump/motor through the rear
washer system plumbing and fittings to the rear
washer nozzle located on the roof panel above the
rear flip-up glass opening. Whenever routing the
washer hose or a wire harness containing a washer
hose, it must be routed away from hot, sharp, or
moving parts; and, sharp bends that might pinch the
hose must be avoided.
REAR WASHER NOZZLE
DESCRIPTION
The rear washer nozzle is a fluidic-type unit con-
structed of molded plastic (Fig. 6). The nozzle is
secured by a snap fit in a dedicated mounting hole
located in the rear edge of the roof panel above the
rear flip-up glass opening and to the right of the
Center High Mounted Stop Lamp (CHMSL) unit. A
rubber gasket on the back of the nozzle seals the noz-
zle to the roof panel opening. The back of the nozzle
includes an integral alignment feature on the left
side, an integral engagement tab on the top, an inte-
gral latch feature on the bottom, and the washer
plumbing nipple which are all concealed between the
outer roof panel and the rear roof inner header. The
rear washer nozzle latch feature is a one time com-
ponent, and will be damaged if the nozzle is removed
from its mounting hole for service. The rear washer
nozzle cannot be adjusted or repaired. If faulty or
damaged, the entire nozzle unit must be replaced.
OPERATION
The rear washer nozzle is designed to dispense
washer fluid into the wiper pattern area on the out-
side of the rear flip-up glass. Pressurized washer
fluid is fed to the nozzle from the washer reservoir by
the washer pump/motor through a single hose, which
is attached to a barbed nipple on the back of the rear
washer nozzle. The rear washer nozzle incorporates a
fluidic design, which causes the nozzle to emit the
pressurized washer fluid as an oscillating stream to
more effectively cover a larger area of the glass area
to be cleaned.
REMOVAL
NOTE: The rear washer nozzle latch feature is a one
time component, and will be damaged if the nozzle is
removed from its mounting hole for service. If
removed from its mounting hole for any reason, the
rear washer nozzle must be replaced with a new unit.
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the bottom of the rear
washer nozzle away from the roof panel until the
latch feature at the bottom of the nozzle that secures
it in the mounting hole of the roof panel snaps.
(2) Pull the rear washer nozzle out from the roof
panel far enough to access the washer hose (Fig. 7).
(3) Disconnect the washer hose from the barbed
nipple on the back of the rear washer nozzle.
(4) Discard the rear washer nozzle.
Fig. 6 Rear Washer Nozzle
1 - ENGAGEMENT TAB (TOP)
2 - GASKET
3 - REAR WASHER NOZZLE
4 - ALIGNMENT FEATURE
5 - ORIFICE
6 - LATCH FEATURE (BOTTOM)
7 - NIPPLE
8R - 36 REAR WIPERS/WASHERSKJ
REAR WASHER HOSES/TUBES (Continued)

WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION...... 8Wa-01-1
COMPONENT INDEX................. 8Wa-02-1
POWER DISTRIBUTION.............. 8Wa-10-1
JUNCTION BLOCK................... 8Wa-12-1
GROUND DISTRIBUTION............. 8Wa-15-1
BUS COMMUNICATIONS............. 8Wa-18-1
CHARGING SYSTEM................. 8Wa-20-1
STARTING SYSTEM................. 8Wa-21-1
FUEL/IGNITION SYSTEM............. 8Wa-30-1
TRANSMISSION CONTROL SYSTEM.... 8Wa-31-1
VEHICLE SPEED CONTROL........... 8Wa-33-1
ANTILOCK BRAKES.................. 8Wa-35-1
VEHICLE THEFT SECURITY SYSTEM.... 8Wa-39-1
INSTRUMENT CLUSTER.............. 8Wa-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . 8Wa-41-1
AIR CONDITIONING-HEATER.......... 8Wa-42-1
AIRBAG SYSTEM................... 8Wa-43-1
INTERIOR LIGHTING................. 8Wa-44-1BODY CONTROL MODULE............ 8Wa-45-1
AUDIO SYSTEM.................... 8Wa-47-1
REAR WINDOW DEFOGGER........... 8Wa-48-1
OVERHEAD CONSOLE................ 8Wa-49-1
FRONT LIGHTING................... 8Wa-50-1
REAR LIGHTING.................... 8Wa-51-1
TURN SIGNALS..................... 8Wa-52-1
WIPERS........................... 8Wa-53-1
TRAILER TOW...................... 8Wa-54-1
POWER WINDOWS.................. 8Wa-60-1
POWER DOOR LOCKS............... 8Wa-61-1
POWER MIRRORS.................. 8Wa-62-1
POWER SEAT...................... 8Wa-63-1
POWER SUNROOF.................. 8Wa-64-1
SPLICE INFORMATION............... 8Wa-70-1
CONNECTOR PIN-OUTS.............. 8Wa-80-1
CONNECTOR/GROUND/
SPLICE LOCATION................. 8Wa-91-1 KJWIRING
8Wa-1

TERMINOLOGY
This is a list of terms and definitions used in the
wiring diagrams.
LHD .................Left Hand Drive Vehicles
RHD................Right Hand Drive Vehicles
ATX . . Automatic Transmissions-Front Wheel Drive
MTX....Manual Transmissions-Front Wheel Drive
AT ....Automatic Transmissions-Rear Wheel Drive
MT .....Manual Transmissions-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC..........Double Over Head Cam Engine
Built-Up-Export........ Vehicles Built For Sale In
Markets Other Than North America
Except-Built-Up-Export . . Vehicles Built For Sale In
North America
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies the main circuit, part of the main
circuit, gage of wire, and color (Fig. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
COLOR CODE COLOR
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric
code to identify the wire and it's function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
KJ8W-01 WIRING DIAGRAM INFORMATION8Wa-01-5
WIRING DIAGRAM INFORMATION (Continued)

8W-44 INTERIOR LIGHTING
Component Page
Ash Receiver Lamp.................. 8Wa-44-2
Body Control Module............. 8Wa-44-2, 3, 4
Cargo Lamp....................... 8Wa-44-4
Dome Lamp........................ 8Wa-44-2
Fuse 34....................... 8Wa-44-2, 3, 4
G202............................. 8Wa-44-2
Instrument Cluster.................. 8Wa-44-2Component Page
Junction Block.................. 8Wa-44-2, 3, 4
Left Courtesy Lamp................. 8Wa-44-2
Left Visor/Vanity Lamp............... 8Wa-44-3
Overhead Map/Reading Lamp.......... 8Wa-44-4
Right Courtesy Lamp................ 8Wa-44-2
Right Visor/Vanity Lamp.............. 8Wa-44-3
KJ8W-44 INTERIOR LIGHTING8Wa-44-1

INSTALLATION
(1) Connect necessary wiring into electrical con-
nectors. Connect 4±wire connector to upper section of
pump module.
(2) Position sending unit to pump module. Slide
and snap into place.
(3) Install lower section of fuel pump module.
Refer to Fuel Pump Module Removal/Installation.
FUEL LINES
DESCRIPTION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM MAY BE UNDER A
CONSTANT PRESSURE (EVEN WITH THE ENGINE
OFF). BEFORE SERVICING ANY FUEL SYSTEM
HOSES, FITTINGS, LINES, OR MOST COMPO-
NENTS, FUEL SYSTEM PRESSURE MUST BE
RELEASED. REFER TO THE FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
QUICK CONNECT FITTING
DESCRIPTION
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Some are equipped with
safety latch clips. Some may require the use of a spe-
cial tool for disconnection and removal. Refer to
Quick-Connect Fittings Removal/Installation for more
information.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Also refer to Fuel Tubes/Lines/Hoses and Clamps.
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Safety latch clips are
used on certain components/lines. Certain fittings
may require use of a special tool for disconnection.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
Fig. 9 FUEL PRESSURE REGULATOR/SENDING
UNIT ELECTRICAL CONNECTOR
1 - UPPER SECTION OF PUMP MODULE
2 - QUICK-CONNECT FITTINGS
3 - FUEL PRESSURE REGULATOR
4 - 4-WIRE ELECTRICAL CONNECTOR
5 - FUEL TANK CHECK (CONTROL) VALVE
14 - 10 FUEL DELIVERYKJ
FUEL LEVEL SENDING UNIT / SENSOR (Continued)

CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure.
(2) Disconnect negative battery cable from battery.
(3) Clean fitting of any foreign material before dis-
assembly.
(4)2±Button Type Fitting:This type of fitting is
equipped with a push-button located on each side of
quick-connect fitting (Fig. 10). Press on both buttons
simultaneously for removal.
(5)Single-Tab Type Fitting:This type of fitting
is equipped with a single pull tab (Fig. 11). The tab is
removable. After tab is removed, quick-connect fitting
can be separated from fuel system component.
(a) Press release tab on side of fitting to release
pull tab (Fig. 12).If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) While pressing release tab on side of fitting,
use screwdriver to pry up pull tab (Fig. 12).
(c) Raise pull tab until it separates from quick-
connect fitting (Fig. 13).
(6)Two-Tab Type Fitting:This type of fitting is
equipped with tabs located on both sides of fitting
(Fig. 14). The tabs are supplied for disconnecting
quick-connect fitting from component being serviced.(a) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 14) against sides of
quick-connect fitting with your fingers. Tool use is
not required for removal and may damage plastic
retainer.
(b) Pull fitting from fuel system component
being serviced.
(c) The plastic retainer will remain on compo-
nent being serviced after fitting is disconnected.
The o-rings and spacer will remain in quick-con-
nect fitting connector body.
Fig. 10 2-BUTTON TYPE FITTING
1 - QUICK-CONNECT FITTING
2 - PUSH-BUTTONS (2)
Fig. 11 SINGLE-TAB TYPE FITTING
1 - PULL TAB
2 - QUICK-CONNECT FITTING
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
Fig. 12 DISCONNECTING SINGLE-TAB TYPE
FITTING
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING
KJFUEL DELIVERY 14 - 11
QUICK CONNECT FITTING (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................3
STANDARD PROCEDURE - HEAT STAKING . . 3
SPECIFICATIONS........................4
SPECIAL TOOLS
BODY...............................5BODY STRUCTURE.......................6
HOOD................................119
DOOR - FRONT........................121
DOORS - REAR........................128
SWING GATE..........................135
EXTERIOR............................140
INSTRUMENT PANEL....................147
INTERIOR.............................156
PAINT................................162
SEATS...............................164
STATIONARY GLASS....................172
SUNROOF.............................175
WEATHERSTRIP/SEALS..................185
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
²USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL±BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DaimlerChrysler Corporation uses many different
types of push-in fasteners to secure the interior and
exterior trim to the body. Most of these fasteners can
be reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component being
removed. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
KJBODY 23 - 1

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)

DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessivewear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger's clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker, and safety latch should be lubricated period-
ically.
(5) The door lock cylinders should be lubricated
twice each year (preferably autumn and spring).
²Spray a small amount of lock cylinder lubricant
directly into the lock cylinder.
²Apply a small amount to the key and insert it
into the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with
a clean cloth to avoid soiling of clothing.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
KJBODY 23 - 3
BODY (Continued)