2002 JEEP LIBERTY brake lines

INSTALLATION
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the top of the
brake hose at the vehicle (Fig. 8).(3) Install the brake hose banjo bolt at the caliper.
(4) Lower the vehicle and remove the support.
(5) Install the brake line to the brake hose inside
the engine compartment by the front control arm
bolt.
(6) Remove the prop rod from the brake pedal.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 7).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 7).
(4) Install the vent tube (Fig. 7).
(5) Install the brake hose mounting bolt at the top
of the hose located at the body (Fig. 6).
(6) Install the brake line to the hose at the body
(Fig. 6).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
BRAKE PADS / SHOES
DESCRIPTION - REAR DRUM BRAKE
The rear brakes use a leading shoe (primary) and
trailing shoe (secondary) design (Right rear brake is
shown) (Fig. 9).
Fig. 6 BRAKE HOSE AT THE BODY
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BRAKE LINE
4 - COIL SPRING
Fig. 7 BRAKE HOSE AT THE AXLE
1 - REAR WHEEL SPEED SENSOR
2 - BRAKE HOSE
3 - VENT HOSE
4 - BRAKE LINES
5 - MOUNTING BOLT
Fig. 8 BRAKE HOSE MOUNTED
1 - COIL SPRING
2 - MOUNTING BOLT
3 - BRAKE HOSE
4 - FRONT OF THE UPPER CONTROL ARM
5 - 10 BRAKES - BASEKJ
BRAKE LINES (Continued)

JUNCTION BLOCK
DESCRIPTION
The junction block and a rear brake proportioning
valve. The valve is not repairable and must be
replaced as an assembly if diagnosis indicates this is
necessary.
OPERATION
PROPORTIONING VALVE
The proportioning valve is used to balance front-
rear brake action at high decelerations. The valve
allows normal fluid flow during moderate braking.
The valve only controls fluid flow during high decel-
erations brake stops. If the primary brake hydraulic
circuit cannot build pressure a by-pass feature is
activated allowing full flow and pressure to the rear
brakes.
DIAGNOSIS AND TESTING - PROPORTIONING
VALVE
The valve controls fluid flow. If fluid enters the
valve and does not exit the valve the combination
valve must be replaced.
REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the brake lines from the junction
block.
(3) Remove mounting nuts and bolt and remove
the junction block (Fig. 31).
INSTALLATION
(1) Install the junction block on the mounting
studs.
(2) Install mounting nuts and bolt. Tighten to 14
N´m (125 in. lbs.).
(3) Install brake lines to the junction block and
tighten to 20 N´m (180 in. lbs.).
(4) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).
PEDAL
DESCRIPTION
A suspended-type brake pedal is used, the pedal
pivots on a shaft mounted in the steering coloumn
support bracket. The bracket is attached to the dash
panel. The unit is serviced as an assembly, except for
the pedal pad.
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which move the booster
secondary rod. The booster secondary rod depress the
master cylinder piston.
REMOVAL
(1) Remove the knee blocker under the steering
column,(Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - REMOVAL).
(2) Remove the retainer clip securing the booster
push rod to pedal (Fig. 32).
(3) Remove the brake lamp switch,(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(4) Remove the nuts securing the pedal to the col-
umn bracket.
(5) Remove the pedal from the vehicle.
INSTALLATION
(1) Install the pedal into the vehicle.
(2) Install the nuts securing the pedal to the col-
umn bracket.
(3) Tighten the nuts to 22.6 N´m (200 in. lbs.).
(4) Lubricate the brake pedal pin and bushings
with Mopar multi-mileage grease.
(5) Install the booster push rod on the pedal pin
and install a new retainer clip (Fig. 32).
(6) Install the brake lamp switch,(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(7) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
Fig. 31 JUNCTION BLOCK
1 - JUNCTION BLOCK
2 - MOUNTING NUT
5 - 20 BRAKES - BASEKJ

(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)

(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 40).
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return underspring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.
REMOVAL
(1) Siphon and drain the fluid from the reservoir.
(2) Remove the brake lines at the master cylinder.
(3) Disconnect the fluid level electrical connector
from the reservoir.
(4) Remove mounting nuts from the master cylin-
der.
(5) Remove master cylinder.
(6) Remove cylinder cover and drain the rest of the
fluid.
(7) If master cylinder reservoir requires service-
,(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
FLUID RESERVOIR - REMOVAL). (Fig. 41)
INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Clean cylinder mounting surface of brake
booster.
(2) Install master cylinder onto brake booster
studs.
(3) Install mounting nuts and tighten to 25 N´m
(220 in. lbs.).
(4) Connect the brake lines to the master cylinder
and tighten to 20 N´m (180 in. lbs.).
(5) Connect fluid level electrical connector to the
reservoir.
(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
Fig. 38 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 39 TYPICAL - VACUUM CHECK VALVE AND
SEAL
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
Fig. 40 MASTER - TYPICAL
1 - BLEEDING TUBES
2 - RESERVOIR
KJBRAKES - BASE 5 - 25
MASTER CYLINDER (Continued)

the rear brake circuit is pulsed. This allows fluid to
enter the low pressure accumulator (LPA) in the
HCU resulting in a drop in fluid pressure to the rear
brakes. In order to increase the rear brake pressure
the outlet valve is switched off and the inlet valve is
pulsed. This increases the pressure to the rear
brakes. This will continue until the required slip dif-
ference is obtained. At the end of EBD braking (no
brake application) the fluid in the LPA drains back to
the master cylinder by switching on the outlet valve
and draining through the inlet valve check valve. At
the same time the inlet valve is switched on to pre-
vent a hydraulic short circiut in case of another
brake application.The EBD will remain functional
during many ABS fault modes. If the red and amber
warning lamps are illuminated the EBD may have a
fault.
DIAGNOSIS AND TESTING - ANTILOCK
BRAKING SYSTEM
The ABS brake system performs several self-tests
every time the ignition switch is turned on and the
vehicle is driven. The CAB monitors the systems
input and output circuits to verify the system is oper-
ating correctly. If the on board diagnostic system
senses that a circuit is malfunctioning the system
will set a trouble code in its memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Electrical, Electronic Control Mod-
ules section. For test procedures refer to the
Chassis Diagnostic Manual.
STANDARD PROCEDURE - ABS BRAKE
BLEEDING
ABS system bleeding requires conventional bleed-
ing methods plus use of the DRB scan tool. The pro-
cedure involves performing a base brake bleeding,
followed by use of the scan tool to cycle and bleed the
HCU pump and solenoids. A second base brake bleed-
ing procedure is then required to remove any air
remaining in the system.
(1) Perform base brake bleeding,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(2) Connect scan tool to the Data Link Connector.
(3) Select ANTILOCK BRAKES, followed by MIS-
CELLANEOUS, then ABS BRAKES. Follow the
instructions displayed. When scan tool displays TEST
COMPLETE, disconnect scan tool and proceed.
(4) Perform base brake bleeding a second time,(Re-
fer to 5 - BRAKES - STANDARD PROCEDURE) OR
(Refer to 5 - BRAKES - STANDARD PROCEDURE).
(5) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Hydraulic Control
Unit/Controller Antilock
Brakes Mounting Nuts14.1 Ð 125
Hydraulic Control
Unit/Controller Antilock
Brakes Brake Lines20.3 Ð 180
Controller Antilock Brakes
Mounting Screws1.8 Ð 16
Wheel Speed Sensors
Front Mounting Bolt12 Ð 132
Wheel Speed Sensor
Rear Mounting Bolt9Ð80
KJBRAKES - ABS 5 - 33
BRAKES - ABS (Continued)

REMOVAL
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove negative battery cable from the bat-
tery.
(3) Pull up on the CAB harness connector release
(Fig. 3)and remove connector.
(4) Remove brake lines from the HCU.
(5) Remove HCU/CAB mounting nuts and bolt
(Fig. 4) and remove HCU/CAB.
INSTALLATION
(1) Install HCU/CAB on the mounting studs.
(2) Install mounting nuts and bolt. Tighten to 11.5
N´m (102 in. lbs.).
(3) Install brake lines to the HCU and tighten to
19 N´m (170 in. lbs.).
(4) Install wiring harness connector to the CAB
and push down on the release to secure the connec-
tor.
(5) Install negative battery cable to the battery.
(6) Bleed ABS brake system (Refer to 5 - BRAKES
- STANDARD PROCEDURE).Fig. 3 CAB HARNESS CONNECTOR RELEASE
1 - ABS MODULE
2 - ELECTRICAL CONNECTOR
Fig. 4 HCU/CAB MOUNTING
1 - HCU
2 - CAB
3 - HCU/CAB BRACKET
4 - MOUNTING NUTS AND STUDS
5 - MOTOR
5 - 36 BRAKES - ABSKJ
HCU (HYDRAULIC CONTROL UNIT) (Continued)

BRAKES
TABLE OF CONTENTS
page page
POWER BRAKE BOOSTER
REMOVAL - RHD........................1INSTALLATION - RHD.....................1
POWER BRAKE BOOSTER
REMOVAL - RHD
(1) Remove the air box (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
(2) Relocate the cruise control servo to gain access
to the booster for removal.
(3) Remove the brake lines from the master cylin-
der.
(4) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(5) Disconnect vacuum hose from booster check
valve.
(6) Remove knee blocker under the steering colum-
n,(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove the brake light switch.(Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(8) Remove retaining clip that secures booster
push rod to brake pedal (Fig. 1).
(9) Remove nuts attaching booster to the dash
panel (Fig. 2).(10) In engine compartment, slide booster studs
out of dash panel, tilt booster upward, and remove
booster from engine compartment.
INSTALLATION - RHD
(1) Align and position booster on the dash panel.
(2) Install booster mounting nuts. Tighten nuts
just enough to hold booster in place.
(3) Slide booster push rod onto the brake pedal.
Then secure push rod to pedal pin with retaining
clip.
NOTE: Lubricate the pedal pin with Mopar multi-
mileage grease before installation.
(4) Tighten booster mounting nuts to 39 N´m (29
ft. lbs.).
(5) Install the brake light switch.
(6) Install the knee blocker,(Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
(7) If original master cylinder is being installed,
check condition of seal at rear of master cylinder.
Replace seal if cut, or torn.
(8) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
Fig. 1 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 2 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJBRAKES 5s - 1