Table of Contents JEEP LIBERTY 2002 KJ / 1.G Manual Online

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

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS.......................1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT........................2
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT........................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................2DIAGNOSIS AND TESTING - HEATER
PERFORMANCE.......................6
DIAGNOSIS AND TESTING - VACUUM
SYSTEM.............................6
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................9
SPECIFICATIONS
A/C APPLICATION TABLE................9
SPECIFICATIONS.....................10
CONTROLS.............................11
DISTRIBUTION..........................29
PLUMBING.............................38
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel. On heater-only systems, the evaporator coil is
omitted from the housing.
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the HVAC
system, the engine cooling system must be properly
maintained. The use of a bug screen is not recom-
mended. Any obstructions in front of the radiator or
condenser will reduce the performance of the air con-
ditioning and engine cooling systems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Engine Cooling for
more information before the opening of, or attempt-
ing any service to the engine cooling system.
Fig. 1 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
4- BLOWER MOTOR HOUSING
5- EVAPORATOR (A/C ONLY)
6- LOWER HVAC CASE ASSEMBLY
KJHEATING & AIR CONDITIONING 24 - 1

CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH
DESCRIPTION - 3.7L and 2.4L.............12
OPERATION - 3.7L and 2.4L...............12
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL...........12
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN.......12
REMOVAL.............................13
INSPECTION..........................14
INSTALLATION.........................14
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY......................15
REMOVAL.............................16
INSTALLATION.........................16
A/C HEATER CONTROL
DESCRIPTION.........................16
REMOVAL.............................17
INSTALLATION.........................17
A/C HIGH PRESSURE SWITCH
DESCRIPTION.........................17
OPERATION...........................18
DIAGNOSIS AND TESTING - A/C HIGH
PRESSURE SWITCH...................18
REMOVAL.............................18
INSTALLATION.........................18
A/C LOW PRESSURE SWITCH
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING - A/C LOW
PRESSURE SWITCH...................19
REMOVAL.............................19
INSTALLATION.........................19
BLEND DOOR ACTUATOR
REMOVAL.............................20
INSTALLATION.........................20BLOWER MOTOR RELAY
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - BLOWER
MOTOR RELAY.......................21
REMOVAL.............................21
INSTALLATION.........................22
BLOWER MOTOR RESISTOR
DESCRIPTION.........................22
OPERATION...........................22
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR....................22
REMOVAL.............................22
INSTALLATION.........................22
BLOWER MOTOR SWITCH
DESCRIPTION.........................23
OPERATION...........................23
DIAGNOSIS AND TESTING - BLOWER
MOTOR SWITCH......................23
REMOVAL.............................23
INSTALLATION.........................23
MODE DOOR ACTUATOR
REMOVAL
REMOVAL - PANEL DOOR ACTUATOR.....24
REMOVAL - FLOOR - DEFROST DOOR
ACTUATOR..........................24
INSTALLATION
INSTALLATION - PANEL DOOR ACTUATOR . 25
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR..........................25
RECIRCULATION DOOR ACTUATOR
REMOVAL.............................26
INSTALLATION.........................26
VACUUM CHECK VALVE
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................28
INSTALLATION.........................28
KJCONTROLS 24 - 11

DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION - DEMISTER OUTLETS.......29
REMOVAL - PANEL OUTLET BARRELS......29
INSTALLATION - PANEL OUTLET BARRELS . . . 29
BLOWER MOTOR
DESCRIPTION.........................30
OPERATION...........................30
DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................30
REMOVAL.............................30
INSTALLATION.........................31
FLOOR CONSOLE DUCT
REMOVAL.............................31
INSTALLATION.........................31
FLOOR DUCT
REMOVAL.............................32
INSTALLATION.........................32
DEFROST - DEMISTER DUCT
REMOVAL - DEFROST DUCT/DEMISTER
ADAPTOR...........................32INSTALLATION - DEFROST/DEMISTER DUCT . 32
HVAC HOUSING
REMOVAL.............................33
DISASSEMBLY.........................34
ASSEMBLY............................34
INSTALLATION.........................34
BLEND DOOR
REMOVAL.............................35
INSTALLATION.........................35
MODE DOOR
REMOVAL
REMOVAL - DEFROST DOOR............35
REMOVAL - FLOOR - DEFROST DOOR....36
INSTALLATION
INSTALLATION - PANEL DOOR...........36
INSTALLATION - FLOOR - DEFROST DOO . . 37
RECIRC DOOR
REMOVAL.............................37
INSTALLATION.........................37
AIR OUTLETS
DESCRIPTION - DEMISTER OUTLETS
The side window demister outlets are integral to
the instrument panel end caps(Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL END
CAP - REMOVAL) and (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL END CAP -
REMOVAL).
REMOVAL - PANEL OUTLET BARRELS
(1) Use a trim stick or another suitable wide flat-
bladed tool to gently pry the panel outlet barrels out
of the panel outlet housing (Fig. 1). The barrel is
retained by a light snap fit.
INSTALLATION - PANEL OUTLET BARRELS
To install, position the barrel in the panel outlet
housing and press firmly until the barrel snaps into
place.
Fig. 1 DASH PANEL OUTLETS
1 - CENTER OUTLETS
2 - SIDE WINDOW DEMISTER OUTLETS
3 - SIDE OUTLETS
4 - WIRING FOR HVAC CONTROL ASSEMBLY
5 - WINDSHIELD DEFROSTER OUTLET
KJDISTRIBUTION 24 - 29

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION - REFRIGERANT LINE.......38
WARNING
SERVICE WARNINGS..................39
CAUTION
SERVICE CAUTIONS..................39
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS.................40
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........40
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................41
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................41
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................41
SPECIFICATIONS - CHARGE CAPACITY.....42
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION........................42
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE..............................42
OPERATION
OPERATION.........................42
OPERATION - HIGH PRESSURE RELIEF
VALVE..............................42
DIAGNOSIS AND TESTING - A/C
COMPRESSOR NOISE.................42
REMOVAL.............................43
INSTALLATION.........................44
A/C CONDENSER
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
A/C DISCHARGE LINE
REMOVAL.............................46INSTALLATION.........................47
A/C LIQUID LINE
REMOVAL.............................47
INSTALLATION.........................47
A/C SUCTION LINE
REMOVAL.............................48
INSTALLATION.........................49
A/C EVAPORATOR
DESCRIPTION.........................49
OPERATION...........................49
REMOVAL.............................49
INSTALLATION.........................49
A/C ORIFICE TUBE
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL.............................50
INSTALLATION.........................50
ACCUMULATOR
DESCRIPTION.........................51
OPERATION...........................51
REMOVAL.............................51
INSTALLATION.........................51
HEATER CORE
DESCRIPTION.........................52
OPERATION...........................52
REMOVAL.............................52
INSTALLATION.........................53
REFRIGERANT
DESCRIPTION.........................53
OPERATION...........................53
REFRIGERANT OIL
DESCRIPTION.........................53
OPERATION...........................54
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL...........................54
PLUMBING
DESCRIPTION - REFRIGERANT LINE
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system on
this vehicle. This nylon tube helps to further containthe R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
24 - 38 PLUMBINGKJ

EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL
SYSTEM.............................1
DESCRIPTION - STATE DISPLAY TEST
MODE...............................2
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE...............................2
DESCRIPTION - DIAGNOSTIC TROUBLE
CODES..............................2DESCRIPTION - TASK MANAGER.........17
DESCRIPTION - MONITORED SYSTEMS . . . 17
DESCRIPTION - TRIP DEFINITION........19
DESCRIPTION - COMPONENT MONITORS . . 19
DESCRIPTION - NON-MONITORED
CIRCUITS...........................20
DESCRIPTION - HIGH AND LOW LIMITS . . . 20
DESCRIPTION - LOAD VALUE...........20
OPERATION - TASK MANAGER............21
EVAPORATIVE EMISSIONS................24
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL SYSTEM
The Powertrain Control Module (PCM) monitors
many different circuits in the fuel injection, ignition,
emission and engine systems. If the PCM senses a
problem with a monitored circuit often enough to
indicate an actual problem, it stores a Diagnostic
Trouble Code (DTC) in the PCM's memory. If the
code applies to a non-emissions related component or
system, and the problem is repaired or ceases to
exist, the PCM cancels the code after 40 warm-up
cycles. Diagnostic trouble codes that affect vehicle
emissions illuminate the Malfunction Indicator Lamp
(MIL). The MIL is displayed as an engine icon on the
instrument panel. Refer to Malfunction Indicator
Lamp (MIL) in this section.
Certain criteria must be met before the PCM
stores a DTC in memory. The criteria may be a spe-
cific range of engine RPM, engine temperature,
and/or input voltage to the PCM.
The PCM might not store a DTC for a monitored
circuit even though a malfunction has occurred. This
may happen because one of the DTC criteria for the
circuit has not been met.For example, assume the
diagnostic trouble code criteria requires the PCM to
monitor the circuit only when the engine operates
between 750 and 2000 RPM. Suppose the sensor's
output circuit shorts to ground when engine operates
above 2400 RPM (resulting in 0 volt input to the
PCM). Because the condition happens at an engine
speed above the maximum threshold (2000 rpm), the
PCM will not store a DTC.There are several operating conditions for which
the PCM monitors and sets DTC's. Refer to Moni-
tored Systems, Components, and Non-Monitored Cir-
cuits in this section.
Technicians must retrieve stored DTC's by connect-
ing the DRB scan tool (or an equivalent scan tool) to
the 16±way data link connector (Fig. 1).
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16±way data link connector to erase all
DTC's and extinguish the MIL.
Fig. 1 DATA LINK CONNECTOR LOCATION
KJEMISSIONS CONTROL 25 - 1

EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAPORATION CONTROL
SYSTEM............................24
SPECIFICATIONS
TORQUE............................26
EVAP/PURGE SOLENOID
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................27
FUEL FILLER CAP
DESCRIPTION.........................27
OPERATION...........................27
LEAK DETECTION PUMP
DESCRIPTION.........................27
OPERATION...........................28
REMOVAL.............................28INSTALLATION.........................28
ORVR
DESCRIPTION.........................29
OPERATION...........................29
P C V VA LV E
DESCRIPTION.........................29
OPERATION...........................31
DIAGNOSIS AND TESTING - PCV VALVE.....31
REMOVAL.............................32
INSTALLATION.........................32
VACUUM LINES
DESCRIPTION.........................33
VAPOR CANISTER
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................33
INSTALLATION.........................33
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAPORATION CONTROL
SYSTEM
The evaporation control system prevents the emis-
sion of fuel tank vapors into the atmosphere. When
fuel evaporates in the fuel tank, the vapors pass
through the control valve located in the top section of
the fuel pump module, through the fuel management
valve, and through vent hoses and tubes to a char-
coal filled evaporative canister. The canister tempo-
rarily holds the vapors. The Powertrain Control
Module (PCM) allows intake manifold vacuum to
draw vapors into the combustion chambers during
certain operating conditions.
Gas powered engines use a duty cycle purge sys-
tem. The PCM controls vapor flow by operating theduty cycle EVAP purge solenoid. Refer to Duty Cycle
EVAP Canister Purge Solenoid.
When equipped with certain emissions packages, a
Leak Detection Pump (LDP) will be used as part of
the evaporative system for OBD II requirements.
Also refer to Leak Detection Pump.
Vehicles powered with gasoline engines are also
equipped with ORVR (On-Board Refueling Vapor
Recovery). Refer to ORVR for additional information.
NOTE: The evaporative system uses specially man-
ufactured lines/hoses. If replacement becomes nec-
essary, only use fuel resistant, low permeation
hose.
Certain components can be found in (Fig. 1).
25 - 24 EVAPORATIVE EMISSIONSKJ

FOREWORD
This manual is designed as a supplement to be used along with the 2002 Liberty service manual,
81-370-02060. It includes information related to the 2.4L gas engine installed in this vehicle by
DaimlerChrysler Corporation. For diagnosis or service procedures relating to other components or systems,
refer to the 2002 Liberty Service Manual.
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

INTRODUCTION
TABLE OF CONTENTS
page page
FASTENER IDENTIFICATION
DESCRIPTION..........................1
FASTENER USAGE
DESCRIPTION
DESCRIPTION........................4
DESCRIPTION........................4
THREADED HOLE REPAIR
DESCRIPTION..........................4
INTERNATIONAL SYMBOLS
DESCRIPTION..........................4
METRIC SYSTEM
DESCRIPTION..........................5TORQUE REFERENCES
DESCRIPTION..........................7
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION..........................8
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION..........................9
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of linemarks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 1) and (Fig. 2).
KJINTRODUCTION 1