2002 JEEP LIBERTY interior

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Page 1627 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES.........162
PAINT CODE
DESCRIPTION........................162
BASE COAT/CLEAR COAT FINISH
DESCRIPTION........................162PAI

Page 1635 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual SEAT BACK CUSHION - REAR
REMOVAL
(1) Remove the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - REAR -
REMOVAL)
(2) Separate the cushion from the seat back frame.
INSTALLATION
(1) Positio

Page 1636 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual INSTALLATION
(1) Position the striker and install the bolts.
(2) Tighten the bolts to 35 N´m (26 ft. lbs.).
(3) Install the quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTA

Page 1637 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual STATIONARY GLASS
TABLE OF CONTENTS
page page
DOOR GLASS
REMOVAL............................172
INSTALLATION........................172
QUARTER WINDOW
REMOVAL............................172
INSTALLATIO

Page 1638 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT

WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
²URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
²DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
²BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
²VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
²SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
²ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR -
REMOVAL)
(2) Remove cowl cover. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL)(3) Remove screws attaching windshield side mold-
ing to A-pillar.
(4) Remove upper windshield molding.
(5) Cut urethane bonding from around windshield
using a suitable sharp cold knife. A pneumatic cut-
ting device can be used if available.
(6) Separate windshield from vehicle.
INSTALLATION
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
CAUTION: Open a window before installing wind-
shield. This will avoid pressurizing the passenger
compartment. If a door or swing gate flip-up glass
is slammed before urethane is cured, water leaks
can result.
The windshield fence should be cleaned of old ure-
thane bonding material. Support spacers should be
cleaned and properly installed on weld studs or
repair screws at bottom of windshield opening.
(1) Place replacement windshield into windshield
opening. Position glass in the center of the opening
against the support spacers. Mark the glass at the
support spacers with a grease pencil or masking tape
and ink pen to use as a reference for installation.
Remove replacement windshield from windshield
opening.
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart.
(3) Clean inside of windshield with Mopar Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around edge of windshield. Wipe with clean/dry lint-
free cloth.
(5) Apply black-out primer 15 mm (.75 in.) wide on
top and sides of windshield and 25 mm (1 in.) on bot-
tom of windshield. Allow at least three minutes dry-
ing time.
(6) Position windshield spacers on lower fence
above support spacers at the edge of the windshield
opening.
(7) Align the dot on the upper molding to the tick
mark in the center of the glass and install upper
molding onto windshield.
(8) Apply a 10 mm (0.4 in.) bead of urethane
around perimeter of windshield along the inside of
the moldings. Apply two beads along the bottom
edge.
KJSTATIONARY GLASS 23 - 173

Page 1639 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual (9) Apply fence primer around the perimeter of the
windshield opening fence. Allow at least 18 minutes
drying time.
(10) With aid of a helper, position windshield over
windshield opening. Align refere

Page 1650 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR SEAL
REMOVAL............................185
INSTALLATION........................185
COWL WEATHERSTRIP
REMOVAL............................185
INS

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

Page 1654 of 1803

JEEP LIBERTY 2002 KJ / 1.G Workshop Manual DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service p

DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service port
coupler sizes are used on the R-134a system, to
ensure that the refrigerant system is not accidentally
contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
OPERATION
OPERATION - HEATER AND AIR CONDITIONER
The heater and optional air conditioner are blend-
air type systems. In a blend-air system, a blend door
controls the amount of unconditioned air (or cooled
air from the evaporator on models with air condition-
ing) that is allowed to flow through, or around, the
heater core. A temperature control knob on the A/C
Heater control panel determines the discharge air
temperature by controlling an electric actuator,
which moves the blend door. This allows an almost
immediate control of the output air temperature of
the system.
The mode control knob on the heater-only or A/C
Heater control panel is used to direct the conditioned
air to the selected system outlets. Both mode control
switches use engine vacuum to control the mode
doors, which are operated by vacuum actuators.
On all vehicles, the outside air intake can be shut
off by selecting the Recirculation Mode with the
mode control knob. This will operate a vacuum actu-
ated recirculation door that closes off the outside
fresh air intake and recirculates the air that is
already inside the vehicle.
The optional air conditioner for all models is
designed for the use of non-CFC, R-134a refrigerant.
The air conditioning system has an evaporator to cool
and dehumidify the incoming air prior to blending it
with the heated air. This air conditioning system
uses a fixed orifice tube in the liquid line near the
condenser outlet tube to meter refrigerant flow to the
evaporator coil. To maintain minimum evaporator
temperature and prevent evaporator freezing, the
A/C low pressure switch on the accumulator cycles
the compressor clutch.
OPERATION - REFRIGERANT SYSTEM SERVICE
PORT
The high pressure service port is located on the
refrigerant line, near the discharge port of the com-
pressor. The low pressure service port is located on
the liquid line at the side of the engine compartment,
near the condensor.Each of the service ports has a threaded plastic
protective cap installed over it from the factory. After
servicing the refrigerant system, always reinstall
both of the service port caps.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE
The air conditioning system is designed to provide
the passenger compartment with low temperature
and low humidity air. The evaporator, located in the
HVAC housing on the dash panel below the instru-
ment panel, is cooled to temperatures near the freez-
ing point. As warm damp air passes through the
cooled evaporator, the air transfers its heat to the
refrigerant in the evaporator and the moisture in the
air condenses on the evaporator fins. During periods
of high heat and humidity, an air conditioning sys-
tem will be more effective in the Recirculation Mode.
With the system in the Recirculation Mode, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, the air conditioning system performance
levels improve.
Humidity has an important bearing on the temper-
ature of the air delivered to the interior of the vehi-
cle. It is important to understand the effect that
humidity has on the performance of the air condition-
ing system. When humidity is high, the evaporator
has to perform a double duty. It must lower the air
temperature, and it must lower the temperature of
the moisture in the air that condenses on the evapo-
rator fins. Condensing the moisture in the air trans-
fers heat energy into the evaporator fins and tubing.
This reduces the amount of heat the evaporator can
absorb from the air. High humidity greatly reduces
the ability of the evaporator to lower the temperature
of the air.
However, evaporator capacity used to reduce the
amount of moisture in the air is not wasted. Remov-
ing some of the moisture out of the air entering the
vehicle adds to the comfort of the passengers.
Although, an owner may expect too much from the
air conditioning system on humid days. A perfor-
mance test is the best way to determine whether the
system is performing up to standard. This test also
provides valuable clues as to the possible cause of
trouble with the air conditioning system.
Before proceeding, (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION). The air temperature in
the test room and in the vehicle must be a minimum
of 21É C (70É F) for this test.
24 - 2 HEATING & AIR CONDITIONINGKJ
HEATING & AIR CONDITIONING (Continued)

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