Bus JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or
suspension components.6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
KNOCKING, RATTLING
OR SQUEAKING1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
suspension components.2. Inspect, tighten or replace components
as necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/
suspension components.2. Inspect, tighten or replace components
as necessary.
2 - 2 SUSPENSIONKJ
SUSPENSION (Continued)

WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION..........................3
OPERATION............................3
STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT
MEASUREMENT.......................4
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT..................5STANDARD PROCEDURE - TOE
ADJUSTMENT.........................5
STANDARD PROCEDURE - CAMBER,
CASTER AND TOE ADJUSTMENT..........5
SPECIFICATIONS
ALIGNMENT..........................6
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe (Fig. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
²CASTERis the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle forward provides negative caster. Tilting the
top of the knuckle rearward provides positive caster.
Positive caster promotes directional stability. This
angle enables the front wheels to return to a straight
ahead position after turns (Fig. 1)
²CAMBERis the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire (Fig. 1)²TOEis the difference between the leading inside
edges and trailing inside edges of the front tires.
Wheel toe position out of specification cause's unsta-
ble steering, uneven tire wear and steering wheel off-
center. The wheel toe position is thefinalfront
wheel alignment adjustment (Fig. 1)
²THRUST ANGLEis the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle (Fig. 1)
Fig. 1 Wheel Alignment Measurements
1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
4 - TOE-IN
KJWHEEL ALIGNMENT 2 - 3

FRONT
TABLE OF CONTENTS
page page
FRONT
DESCRIPTION..........................7
WARNING.............................7
SPECIFICATIONS
TORQUE CHART......................8
SPECIAL TOOLS
FRONT SUSPENSION...................8
BUSHINGS
REMOVAL - STABILIZER BAR BUSHINGS.....9
INSTALLATION - STABILIZER BAR BUSHINGS . . 9
HUB / BEARING
REMOVAL.............................9
INSTALLATION..........................9
KNUCKLE
REMOVAL.............................9
INSTALLATION..........................9
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................10
LOWER CONTROL ARM
REMOVAL.............................10
INSTALLATION.........................10
SHOCK
REMOVAL
REMOVAL - LEFT SIDE.................11REMOVAL - RIGHT SIDE................11
INSTALLATION
INSTALLATION - LEFT SIDE.............12
INSTALLATION - RIGHT SIDE............12
SPRING
REMOVAL.............................13
INSTALLATION.........................13
CLEVIS BRACKET
REMOVAL.............................13
INSTALLATION.........................13
STABILIZER BAR
REMOVAL.............................14
INSTALLATION.........................14
STABILIZER LINK
REMOVAL.............................14
INSTALLATION.........................14
UPPER CONTROL ARM
REMOVAL
REMOVAL - RIGHT SIDE................14
REMOVAL - LEFT SIDE.................15
INSTALLATION
INSTALLATION - RIGHT SIDE............15
INSTALLATION - LEFT SIDE.............15
FRONT
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub bearings on
the steering knuckle spindles. The double-row hub
bearings are sealed and lubricated for life. The steer-
ing knuckles turn (pivot) on ball joints riveted to the
outboard portion of the control arms. The ball joints
are lubricated for life. (Fig. 1)
WARNING
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
Fig. 1 FRONT SUSPENSION
1-SWAYBAR
2 - SWAY BAR BUSHING/BRACKET
3 - UPPER CONTROL ARM
4 - SPRING / SHOCK ASSEMBLY
5 - STEERING KNUCKLE
6 - OUTER TIE ROD END
7 - LOWER CONTROL ARM
8 - SWAY BAR LINK
9 - CLEVIS BRACKET
KJFRONT 2 - 7

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front Shock Absorber Clevis Bracket Upper Nut 136 100 Ð
Front Shock Absorber Clevis Bracket Lower Nut 150 110 Ð
Front Shock Absorber Top (4) Mounting Nuts 108 80 Ð
Front Shock to Spring and Insulator Nut 41 30 Ð
Upper Suspension Arm Front Nut 122 90 Ð
Upper Suspension Arm Rear Nut 122 90 Ð
Lower Suspension Arm Front Nut 170 125 Ð
Lower Suspension Arm Rear Nut 170 125 Ð
Stabilizer Bar Clamp Nut 149 110 Ð
Stabilizer Bar Link Upper Nut 136 100 Ð
Stabilizer Bar Link Lower Nut 115 85 Ð
Hub/Bearing
Bolt130 96 Ð
Hub/Bearing
Halfshaft Nut135 100 Ð
Upper Ball Joint Nut 81 60 Ð
Lower Ball Joint Nut 81 60 Ð
Wheel Speed Sensor 13.5 10 Ð
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
2 - 8 FRONTKJ
FRONT (Continued)

BUSHINGS
REMOVAL - STABILIZER BAR BUSHINGS
(1) Raise vehicle on hoist.
(2) Remove the stabilizer bushing clamps.
(3) Remove the stabilizer bushings from the stabi-
lizer bar.
INSTALLATION - STABILIZER BAR BUSHINGS
(1) Install the stabilizer bushings to the stabilizer
bar.
(2) Install the stabilizer bushing clamps. Tighten
the nuts to 149 N´m (110 ft.lbs.).
(3) Lower the vehicle.
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
the caliper securely.
(4) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(5) Remove the wheel speed sensor (Refer to 5 -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - REMOVAL).
(6) Remove the bracket securing the wheel speed
sensor wire.
(7) Remove the axle shaft nut. (if equipped with
four wheel drive)
(8) Remove the three mounting bolts for the hub/
bearing assembly.
(9) Remove the hub/bearing.
INSTALLATION
(1) Install the hub/bearing assembly to the vehicle.
(2) Install the three mounting bolts for the hub/
bearing. Tighten the bolt to 130 N´m (96 ft.lbs.).
(3) Install the axle shaft nut. Tighten the nut to
135 N´m (100 ft.lbs.). (if equipped with four wheel
drive)
(4) Install the bracket to the wheel speed sensor
wire.
(5) Install the wheel speed sensor to the hub.
Tighten the bolt to 13.5 N´m (10 ft.lbs.) (Refer to 5 -BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - INSTALLATION).
(6) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(7) Install the disc brake caliper adapter. Tighten
the nut to 135 N´m (100 ft.lbs.) (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(8) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
KNUCKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the caliper adapter. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
the caliper securely.
(4) Remove the disc brake rotor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(5) Remove the wheel speed sensor. (Refer to 5 -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - REMOVAL).
(6) Remove the axle shaft nut. (if equipped with
four wheel drive)
(7) Remove the hub/bearing. (Refer to 2 - SUS-
PENSION/FRONT/HUB / BEARING - REMOVAL).
(8) Remove the outer tie rod end. (Refer to 19 -
STEERING/LINKAGE/TIE ROD END - REMOVAL).
(9) Remove the lower ball joint nut.
(10) Seperate the lower ball joint from the suspen-
sion arm using tool C±4150A.
(11) Remove the upper ball joint nut.
(12) Seperate the upper ball joint from the knuckle
using tool C±4150A.
(13) Remove the knuckle from the vehicle.
INSTALLATION
(1) Install the knuckle to the vehicle.
(2) Install the upper ball joint nut. Tighten the nut
to 81 N´m (60 ft.lbs.).
(3) Install the lower ball joint nut. Tighten the nut
to 81 N´m (60 ft.lbs.).
(4) Install the outer tie rod end. (Refer to 19 -
STEERING/LINKAGE/TIE ROD END - INSTALLA-
TION).
KJFRONT 2 - 9

STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the upper stabilizer link bolts at the
stabilizer bar.
(4) Remove the stabilizer bar bushing clamps from
the frame (Fig. 8).
(5) Remove the stabilizer bar from the vehicle.
INSTALLATION
(1) Install the stabilizer bar to the vehicle.
(2) Install the stabilizer bar bushing clamps (Fig.
8). Tighten the nuts to 149 N´m (110 ft.lbs.).
(3) Install the upper stabilizer link bolts and
washer at the stabilizer bar. Tighten the bolt to 136
N´m (100 ft.lbs.).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(5) Lower the vehicle.
STABILIZER LINK
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the lower stabilizer link bolt at the
lower control arm.
(4) Remove the upper stabilizer link bolt at the
stabilizer bar.
(5) Remove the stabilizer link. (Fig. 9)
INSTALLATION
(1) Install the stabilizer link (Fig. 9).
(2) Install the upper stabilizer link bolt and
washer at the stabilizer bar. Tighten the bolt to 136
N´m (100 ft.lbs.).
(3) Install the lower stabilizer link bolt and
washer at the lower control arm. Tighten the nut to
115 N´m (85 ft.lbs.).
(4) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
UPPER CONTROL ARM
REMOVAL
REMOVAL - RIGHT SIDE
(1) Raise and support the vehicle.
(2) Remove the right side tire and wheel assembly.
(3) Remove the upper ball joint nut.
(4) Separate the upper ball joint from the steering
knuckle using tool C-4150A.
(5) Lower the vehicle.
(6) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(7) Remove the cruise control servo mounting nuts.
(8) Remove the upper control arm rear bolt.
(9) Remove the upper control arm front bolt.
(10) Remove the upper control arm from the vehi-
cle.
Fig. 8 SWAY BAR
1-SWAYBAR
2 - SWAY BAR BUSHINGS
Fig. 9 STABILIZER BAR LINK
1 - STABILIZER BAR
2 - STABILIZER BAR LINK
2 - 14 FRONTKJ

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION.........................16
WARNING.............................16
DIAGNOSIS AND TESTING - REAR
SUSPENSION........................17
SPECIFICATIONS
TORQUE CHART......................17
SHOCK
REMOVAL.............................18
INSTALLATION.........................18
SPRING
REMOVAL.............................18
INSTALLATION.........................18
JOUNCE BUMPER
REMOVAL.............................19
INSTALLATION.........................19
STABILIZER BAR
REMOVAL.............................19INSTALLATION.........................19
UPPER BALL JOINT
REMOVAL.............................20
INSTALLATION.........................20
UPPER CONTROL ARM
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............20
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............20
REMOVAL.............................20
INSTALLATION.........................21
LOWER CONTROL ARM
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
REAR
DESCRIPTION
The rear suspension (Fig. 1) is comprised of :
²Drive axle
²Shock absorbers
²Coil springs
²Lower suspension arms
²Upper suspension arm
²Stabilizer bar
CAUTION: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear.
WARNING
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
Fig. 1 REAR SUSPENSION
1 - COIL SPRING
2 - UPPER SUSPENSION ARM
3 - STABILIZER BAR
4 - LOWER SUSPENSION ARM
5 - SHOCK
2 - 16 REARKJ

DIAGNOSIS AND TESTING - REAR SUSPENSION
CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose, worn or bent suspension
components.2. Inspect, tighten or replace components
as necessary.
3. Tire pressure. 3. Adjust tire pressure.
VEHICLE PULLS TO ONE
SIDE1. Weak or broken spring. 1. Replace spring.
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.
KNOCKING, RATTLING
OR SQUEAKING1. Worn shock bushings. 1. Replace shock.
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension
components.5. Inspect, tighten or replace components
as necessary.
IMPROPER TRACKING 1. Loose, worn or bent suspension
components.1. Inspect, tighten or replace components
as necessary.
2. Bent axle. 2.Replace axle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 108 80 Ð
Shock Absorber Lower Nut 115 85 Ð
Suspension Arm Upper Ball Joint Nut 95 70 Ð
Suspension Arm Upper Frame Bolts 100 74 Ð
Rear Upper Ball Joint Bracket Bolts 136 100 Ð
Suspension Arms Lower Body/Axle Bracket Nut 163 120 Ð
Suspension Arms Lower Frame Bracket Nut 163 120 Ð
Stabilizer Bar Bolts 99 73 Ð
KJREAR 2 - 17
REAR (Continued)

UPPER BALL JOINT
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the axle. (Fig. 7)
(4) Seperate the ball joint arm assembly from the
differential housing by prying upwards.
INSTALLATION
(1)Raise the rear axle with a hydraulic jack to align
the ball joint with the differential housing bracket.
(2) Insert the ball joint into the differential hous-
ing bracket.
(3) Install the ball joint pinch bolt and tighten to
95 N´m (70 ft. lbs.). (Fig. 7).
(4) Remove the supports and lower the vehicle.
UPPER CONTROL ARM
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint to the top of the differential housing.
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
in compression and shock absorbers in rebound.
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint pinch bolt from the top of
the differential housing bracket (Fig. 7).
(4) Remove partial nuts from the heat shield in
order to lower the shield down enough to get the
proper clearence to remove the right side bolt from
the body.
(5) Remove the upper suspension arm mounting
bolts from the body and remove the arm (Fig. 8).
(6) Remove the support bracket mounting bolts if
needed. (Fig. 9)
Fig. 7 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLTFig. 8 UPPER CONTROL ARM
1 - BODY MOUNTS
2 - UPPER BALL JOINT
3 - STABILIZER BAR
4 - UPPER CONTROL ARM
5 - LOWER CONTROL ARM
Fig. 9 BALL JOINT BRACKET
1 - UPPER BALL JOINT
2 - SUPPORT BRACKET BOLTS
2 - 20 REARKJ

INSTALLATION
(1) Position the upper suspension arm in the
frame rail brackets (Fig. 8).
(2) Install the mounting bolts and tighten to 100
N´m (74 ft. lbs.).
(3) Retighten the heat shield back into place.
(4) Pull the arm down on the differential housing
bracket and install the pinch bolt and nut. Tighten
the nut to 95 N´m (70 ft. lbs.) (Fig. 7).
(5) Remove the supports and lower the vehicle.
LOWER CONTROL ARM
DESCRIPTION
The lower suspension arms are stamped steel and
welded and use voided round bushings at the axle
end and solid rubber at the body end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads.
REMOVAL
(1) Raise the vehicle and support the rear axle.
(2) Remove the stabilizer bar retaining bolts from
the suspension arm.
(3) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 10).
NOTE: When removing the right side suspension
arm from the frame rail it will be necessary to pry
the exhaust over slightly to allow enough clearance
to remove the bolt.
(4) Remove the nut and bolt (Fig. 10) from the
frame rail and remove the lower suspension arm.
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.NOTE: The end of the arm with the voided round
bushing attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight (Fig. 10).
NOTE: When installing the right side suspension
arm to the frame rail it will be necessary to pry the
exhaust over slightly to allow enough clearance to
install the bolt.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(4) Install the stabilizer bar retaining bolts to the
suspension arm.
(5) Remove the supports and lower the vehicle.
(6) With the vehicle on the ground tighten the nut
at the frame to 163 N´m (120 ft. lbs.). Tighten the
nut at the axle bracket to 163 N´m (120 ft. lbs.).
Fig. 10 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
2 - LOWER CONTROL ARM
3 - BODY BRACKET BOLT
KJREAR 2 - 21
UPPER CONTROL ARM (Continued)