wire JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

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

(4) Position the tube in the flaring tool flush with
the top of the tool bar (Fig. 3). Then tighten the tool
bar on the tube.
(5) Install the correct size adaptor on the flaring
tool yoke screw.
(6) Lubricate the adaptor.
(7) Align the adaptor and yoke screw over the tube
(Fig. 3).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.
REMOVAL
REMOVAL - FRONT HOSE
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the brake line from the brake hose
inside the engine compartment by the front control
arm bolt (Fig. 4).
(3) Raise and support vehicle.
(4) Remove the brake hose banjo bolt at the cali-
per.
(5) Remove the mounting bolt for the top of the
brake hose at the vehicle (Fig. 5).
(6) Remove the hose.
REMOVAL - REAR BRAKE HOSE
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the brake line from the hose at the
body (Fig. 6).
(4) Remove the brake hose mounting bolt at the
top of the hose located at the body (Fig. 6).
(5) Remove the vent tube (Fig. 7).
(6) Remove the two brake lines at the bottom of
the hose located at the axle (Fig. 7).
(7) Remove the mounting bolt for the brake hose
at the axle (Fig. 7).
(8) Remove the hose.
Fig. 3 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
Fig. 4 INNER FENDER BRAKE LINE
1 - GROMMET
2 - BRAKE LINE
Fig. 5 FRONT BRAKE HOSE
1 - TOP OF FRONT BRAKE HOSE
2 - WHEEL SPEED SENSOR WIRE
3 - UPPER CONTROL ARM
KJBRAKES - BASE 5 - 9
BRAKE LINES (Continued)

(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 35).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
REMOVAL
(1) Disconnect the wire to the fluid level switch at
the bottom of the reservoir.(2) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(3) Disconnect vacuum hose from booster check
valve.
(4) Remove the brake lines from the master cylin-
der and the HCU (abs vehicles only) or the junction
block for clearence.
(5) Disconnect the HCU from the mounts and
move to the side for clearence of the booster.
Fig. 33 Power Brake Booster±Typical
1 - VACUUM CHECK VALVE
2 - FRONT DIAPHRAGM
3 - REAR DIAPHRAGM
4 - HOUSING
5 - SEAL
6 - AIR FILTER7 - PRIMARY PUSH ROD (TO BRAKE PEDAL)
8 - ATMOSPHERIC INLET VALVE ASSEMBLY
9 - BOOSTER MOUNTING STUDS (4)
10 - SECONDARY PUSH ROD (TO MASTER CYLINDER)
11 - MASTER CYLINDER MOUNTING STUD (2)
12 - SPRING
5 - 22 BRAKES - BASEKJ
POWER BRAKE BOOSTER (Continued)

(4) Tighten booster mounting nuts to 22.6 N´m
(200 ft. lbs.).
(5) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(6) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(7) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
this purpose. Dirt, grease, or similar materials will
prevent proper cylinder seating and could result in
vacuum leak.
(8) Align and install master cylinder on the
booster studs. Install mounting nuts and tighten to
22.6 N´m (200 in. lbs.).
(9) Connect vacuum hose to booster check valve.
(10) Remount the HCU. Tighten bracket mounting
nuts to 22.6 N´m (200 in. lbs.).
(11) Connect and secure the brake lines to HCU or
junction block and master cylinder. Start all brake
line fittings by hand to avoid cross threading.
(12) Connect the wire to fluid level switch at the
bottom of the reservoir.
(13) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(14) Verify proper brake operation before moving
vehicle.
MASTER CYLINDER
DESCRIPTION
The master cylinder has a removable nylon reser-
voir. The cylinder body is made of aluminum and
contains a primary and secondary piston assembly.
The cylinder body including the piston assemblies
are not serviceable. If diagnosis indicates an internal
problem with the cylinder body, it must be replaced
as an assembly. The reservoir and grommets are the
only replaceable parts on the master cylinder.
OPERATION
The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
The master cylinder reservoir stores reserve brake
fluid for the hydraulic brake circuits.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
age).
(5) Start engine and note pedal action. It should
fall away slightly under light foot pressure then hold
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) If the POWER BOOSTER VACUUM TEST
passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
rpm, close the throttle and immediately turn off igni-
tion to stop engine.
(7) Wait a minimum of 90 seconds and try brake
action again. Booster should provide two or more vac-
uum assisted pedal applications. If vacuum assist is
not provided, booster is faulty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 38).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 39).
(5) Vacuum should hold steady. If gauge on pump
indicates vacuum loss, check valve is faulty and
should be replaced.
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise.
5 - 24 BRAKES - BASEKJ
POWER BRAKE BOOSTER (Continued)

(3) Push the cables thru the floor and seat the
grommets.
(4) Reconnect the two cables to the front mount.
(5) Install the cable saddle bracket (Fig. 47).
(6) Lay the carpet back down in the rear.
(7) Install the rear seat (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION).
(8) Remove the lock out device on the lever.
(9) Test the parking brake.
LEVER
REMOVAL
The center floor console must be removed to service
the parking brake lever,(Refer to 23 - BODY/INTERI-
OR/FLOOR CONSOLE - REMOVAL) .
(1) Lock out the parking brakes (Refer to 5 -
BRAKES/PARKING BRAKE - ADJUSTMENTS).
(2) Disengage the front cables from the equalizer
(Fig. 49).
(3) Disconnect the parking brake lamp switch wire
(Fig. 49).
(4) Remove the parking brake lever assembly
mounting bolts (Fig. 50).
(5) Remove the lever assembly.
INSTALLATION
(1) Install the parking brake lever assembly.
(2) Install the parking brake lever assembly to the
mounting bolts. Tighten (Fig. 50).
Install the center floor console, (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - INSTALLA-
TION).
(3) Engage the front cables to the equalizer (Fig.
49).(4) Reconnect the parking brake lamp switch wire
(Fig. 49).
(5) If installing a new parking brake lever remove
the pin that come on the lever when shipped.
(6) If you are reinstalling the original park brake
lever remove the lock out device at this time.
(7) Test the parking brake lever. (Fig. 50).
Fig. 48 CABLE FRONT MOUNT
1 - RETAINER CLIPS
2 - CABLES
Fig. 49 PARKING BRAKE LEVER
1 - PARK BRAKE LEVER ASSEMBLY
2 - EQUALIZER
Fig. 50 LEVER MOUNT
1 - ELECTRICAL CONNECTOR
2 - PARK BRAKE LEVER ASSEMBLY
3 - CABLE
KJBRAKES - BASE 5 - 31
CABLES (Continued)

ELECTRICAL
DESCRIPTION
Three wheel speed sensors are used. The front sen-
sors are mounted to the steering knuckles. The rear
sensor is mounted at the top of the rear axle differ-
ential carrier. Tone wheels are mounted to the out-
board ends of the front axle shafts. The gear type
tone wheel serves as the trigger mechanism for each
sensor.
OPERATION
The sensors convert wheel speed into a small digi-
tal signal. The CAB sends 12 volts to the sensors.
The sensor has an internal magneto resistance
bridge that alters the voltage and amperage of the
signal circuit. This voltage and amperage is changed
by magnetic induction when the toothed tone wheel
passes the wheel speed sensor. This digital signal is
sent to the CAB. The CAB measures the voltage and
amperage of the digital signal for each wheel.
FRONT WHEEL SPEED
SENSOR
REMOVAL
(1) Disconnect the front wheel speed sensor wire
connector that is located on the inboard side of the
respective wheel house.
(2) Raise and support the vehicle.
(3) Remove the tire and wheel assembly.
(4) 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 with result. Provide a suitable support to hang
the caliper securely.
(5) Remove the disc brake rotor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(6) Remove the wheel speed sensor mounting bolt
to the hub (Fig. 1).
(7) Remove the wheel speed sensor wire from the
hub/bearing (Fig. 1).
(8) Remove the wheel speed sensor wire hold down
from the knuckle (Fig. 1).
(9) Remove the wheel speed sensor wire thru the
wheel well.
(10) Remove the wheel speed sensor from the vehi-
cle.
INSTALLATION
(1) Install the wheel speed sensor to the vehicle.
(2) Install the wheel speed sensor wire thru the
wheel well.
(3) Install the wheel speed sensor wire to the hub/
bearing.
(4) Install the wheel speed sensor wire hold down
to the knuckle.
(5) Install the wheel speed sensor mounting bolt to
the hub. Tighten the mounting bolt to 14 N´m (10
ft.lbs.).
(6) Install the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(7) Install the disc brake caliper adapter. (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Reconnect the front wheel speed sensor wire
connector to the inboard side of the wheel house
being worked on.
Fig. 1 FRONT WHEEL SPEED SENSOR
1 - WHEEL SPEED SENSOR WIRE
2 - WHEEL SPEED SENSOR
3 - ROTOR
4 - WHEEL SPEED SENSOR WIRE HOLD DOWN
5 - 34 BRAKES - ABSKJ

REAR WHEEL SPEED SENSOR
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the sensor wire harness.
(3) Remove mounting stud from the sensor (Fig. 2).
(4) Remove sensor.
INSTALLATION
(1) Connect harness to sensor.Be sure seal is
securely in place between sensor and wiring
connector.
(2) Install O-ring on sensor (if removed).
(3) Insert sensor in differential housing.
(4) Install the sensor mounting stud and tighten to
9 N´m (80 in. lbs.).
(5) Install the sensor electical connector.
(6) Lower vehicle.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consists of a valve body, pump motor,
and wire harness.
OPERATION
Accumulators in the valve body store extra fluid
released to the system for ABS mode operation. The
pump provides the fluid volume needed and is oper-
ated by a DC type motor. The motor is controlled by
the CAB.The valves modulate brake pressure during
antilock braking and are controlled by the CAB.
The HCU provides three channel pressure control
to the front and rear brakes. One channel controls
the rear wheel brakes in tandem. The two remaining
channels control the front wheel brakes individually.
During antilock braking, the solenoid valves are
opened and closed as needed. The valves are not
static. They are cycled rapidly and continuously to
modulate pressure and control wheel slip and decel-
eration.
During normal braking, the HCU solenoid valves
and pump are not activated. The master cylinder and
power booster operate the same as a vehicle without
an ABS brake system.
During antilock braking, solenoid valve pressure
modulation occurs in three stages, pressure increase,
pressure hold, and pressure decrease. The valves are
all contained in the valve body portion of the HCU.
PRESSURE DECREASE
The outlet valve is opened and the inlet valve is
closed during the pressure decrease cycle.
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet
then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is
allowed to bleed off (decrease) as needed to prevent
wheel lock.
Once the period of high wheel slip has ended, the
CAB closes the outlet valve and begins a pressure
increase or hold cycle as needed.
PRESSURE HOLD
Both solenoid valves are closed in the pressure
hold cycle. Fluid apply pressure in the control chan-
nel is maintained at a constant rate. The CAB main-
tains the hold cycle until sensor inputs indicate a
pressure change is necessary.
PRESSURE INCREASE
The inlet valve is open and the outlet valve is
closed during the pressure increase cycle. The pres-
sure increase cycle is used to counteract unequal
wheel speeds. This cycle controls re-application of
fluid apply pressure due to changing road surfaces or
wheel speed.
Fig. 2 REAR WHEEL SPEED SENSOR
1 - DIFFERENTIAL HOUSING
2 - MOUNTING BOLT
3 - WHEEL SPEED SENSOR
KJBRAKES - ABS 5 - 35

this purpose. Dirt, grease, or similar materials will
prevent proper cylinder seating and could result in
vacuum leak.
(9) Align and install master cylinder on the
booster studs. Install mounting nuts and tighten to
17.5 N´m (155 in. lbs.).
(10) Connect vacuum hose to booster check valve.
(11) Remount the cruise control servo to the origi-
nal location. Tighten bracket mounting nuts to 17.5
N´m (155 in. lbs.).(12) Connect and secure the brake lines to HCU
and master cylinder. Start all brake line fittings by
hand to avoid cross threading.
(13) Connect the wire to fluid reservoir.
(14) Install the air box.
(15) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(16) Verify proper brake operation before moving
vehicle.
5s - 2 BRAKESKJ
POWER BRAKE BOOSTER (Continued)

this purpose. Dirt, grease, or similar materials will
prevent proper cylinder seating and could result in
vacuum leak.
(9) Align and install master cylinder on the
booster studs. Install mounting nuts and tighten to
17.5 N´m (155 in. lbs.).
(10) Connect vacuum hose to booster check valve.
(11) Remount the cruise control servo to the origi-
nal location. Tighten bracket mounting nuts to 17.5
N´m (155 in. lbs.).(12) Connect and secure the brake lines to HCU
and master cylinder. Start all brake line fittings by
hand to avoid cross threading.
(13) Connect the wire to fluid reservoir.
(14) Install the air box.
(15) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(16) Verify proper brake operation before moving
vehicle.
5s - 2 BRAKESKJ
POWER BRAKE BOOSTER (Continued)

(9) Slide actuator off pivot pin.
(10) Disconnect clutch interlock safety switch
wires.(11) Remove clutch hydraulic linkage through
engine compartment.
INSTALLATION
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Be sure reservoir cover on clutch master cylin-
der is tight to avoid spills.
(2) Position clutch linkage components in vehicle.
Work connecting line and slave cylinder downward
past engine and adjacent to clutch housing.
(3) Position clutch master cylinder on dash panel.
(4) Attach clutch master cylinder actuator to pivot
pin on clutch pedal.
(5) Install and tighten clutch master cylinder
attaching nuts to 38 N´m (28 ft. lbs.).
(6) Raise vehicle.
(7) Insert slave cylinder push rod through clutch
housing opening and into release lever. Be sure cap
on end of rod is securely engaged in lever. Check this
before installing cylinder attaching nuts.
(8) Install and tighten slave cylinder attaching
nuts to 23 N´m (17 ft. lbs.).
(9) Secure clutch fluid line in body and transmis-
sion clips.
(10) Lower vehicle.
(11) Connect clutch interlock safety switch wires.
MASTER CYLINDER
INSPECTION
The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are pre-filled with fluid at
the factory during assembly operations.
The hydraulic system should not require additional
fluid under normal circumstances.The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling or remov-
ing fluid from the reservoir.
Clutch fluid level is checked at the master cylinder
reservoir. An indicator ring is provided on the outside
of the reservoir. With the cap and diaphragm
removed, fluid level should not be above indicator
ring.
To avoid contaminating the hydraulic fluid during
inspection, wipe reservoir and cover clean before
removing the cap.
Fig. 6 SLAVE CYLINDER
1 - CLUTCH SLAVE CYLINDER
Fig. 7 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
KJCLUTCH 6 - 9
LINKAGE (Continued)