2002 JEEP LIBERTY Workshop Manual

CONTROL SWITCH
DESCRIPTION
Vehicles equipped with a power sunroof utilize an
sunroof control switch. On this model, the sunroof
control switch is located in the overhead console, in
between the two reading lamps. The switch is
mounted in the overhead console with four plastic
retaining tabs, molded into the switch housing.
This switch incorporates four selections of opera-
tion open, auto open, close and vent. The individual
switches in the sunroof control switch unit cannot be
repaired. If one switch is damaged or faulty, the
entire sunroof control switch unit must be replaced.
OPERATION
With the operation of the sunroof control switch,
voltage is directed to the sunroof motor, through the
switch contacts or control module. If the control
switch is depressed and held depressed the voltage
signal is controlled manually through the switch con-
tacts, so when the switch is released the sunroof
stops.
Refer to the owners manual for more information
on the operation of the sunroof switch and system.
DIAGNOSIS AND TESTING
The following test will determine if the sunroof
control switch is operating properly.
(1) Remove the overhead console from the head-
liner (Refer to 8 - ELECTRICAL/OVERHEAD CON-
SOLE - REMOVAL).
(2) Remove the sunroof control switch from the
overhead console (Refer to 23 - BODY/SUNROOF/
CONTROL SWITCH - REMOVAL).
(3) Using an ohmmeter, test the switch terminals
for proper continuity using the table below. If any ofthe terminals do not show proper continuity, replace
the sunroof control switch.
SWITCH POSITION
(DEPRESSED)CONTINUITY BETWEEN
TERMINALS
VENT (V) 3, 4
OPEN (AUTO) 1, 4
CLOSE 2, 4
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the overhead console from the head-
liner (Refer to 8 - ELECTRICAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Disconnect the sunroof control switch electrical
connector. Depress the connector retaining tab and
pull the connector straight out.
(4) To remove the switch from the overhead con-
sole, push on the back of the switch until it comes
free from the overhead console.
INSTALLATION
(1) Install the switch in the overhead console
assembly. Be certain the switch is securely snapped
in place.
(2) Connect the sunroof control switch electrical
connector. Be certain the switch connector is securely
snapped in place.
(3) Install the overhead console (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION).
(4) Connect the negative battery cable.
23 - 184 SUNROOFKJ

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

(4) When installing a new weatherstrip on the rear
door opening, remove the tear strip starting at the
splice and moving around the back of the door to the
front of the opening.
DOOR LOWER WEATHERSTRIP
REMOVAL
(1) Carefully disengage the push pin fasteners and
remove the seal.
INSTALLATION
(1) Position the seal and seat the push pin fasten-
ers.
FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Lower the window.
(2) Pull the outer belt molding off of the door
flange starting at the rear and moving forward.
INSTALLATION
(1) Press the belt molding onto the outer door win-
dow flange starting at the rear and working forward.
SWING GATE BELTLINE
WEATHERSTRIP
REMOVAL
(1) Remove the swing gate trim panel. (Refer to 23
- BODY/SWING GATE/TRIM PANEL - REMOVAL)
(2) Pull seal away from the corner tabs and
remove from the swing gate flange.
INSTALLATION
(1) Install the seal over the swing gate flange and
seat the corner tabs.
(2) Install the swing gate trim panel. (Refer to 23 -
BODY/SWING GATE/TRIM PANEL - INSTALLA-
TION)
SWING GATE OPENING
WEATHERSTRIP
REMOVAL
(1) Open the swing gate and peal seal off of the
gate opening flange.
INSTALLATION
(1) Position the seal to the bottom of the gate
opening starting the installation at the center of the
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.
REAR DOOR OUTER BELT
MOLDING
REMOVAL
(1) Lower the window.
(2) Pull the outer belt molding off of the door
flange starting at the rear and moving forward.
INSTALLATION
(1) Press the belt molding onto the outer door win-
dow flange starting at the front and working back.
SIDE RAIL WEATHERSTRIP/
RETAINER
REMOVAL
(1) Remove the windshield weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/
WINDSHIELD A-PILLAR WEATHERSTRIP/RE-
TAINER - REMOVAL)
(2) Remove the two screws.
(3) Using a trim stick C-4755 or equivalent,
release the push in fasteners and remove the weath-
erstrip.
INSTALLATION
(1) Position the weatherstrip and seat the push in
fasteners.
(2) Install the two screws.
(3) Install the windshield weatherstrip. (Refer to
23 - BODY/WEATHERSTRIP/SEALS/WINDSHIELD
A-PILLAR WEATHERSTRIP/RETAINER - INSTAL-
LATION)
WINDSHIELD A-PILLAR
WEATHERSTRIP/RETAINER
REMOVAL
(1) Open the doors and peal the a-pillar seal away
from the a-pillar/windshield and the side rail
weather strip flanges.
(2) Remove the seven screws and remove the
weatherstrip.
23 - 186 WEATHERSTRIP/SEALSKJ
DOOR PRIMARY WEATHERSTRIP (Continued)

INSTALLATION
(1) Position the weatherstrip and install the seven
screws.
(2) Position the a-pillar seal over the windshield/a-
pillar and the side rail weatherstrip flanges and seat
fully.
COWL/PLENUM SEAL
REMOVAL
(1) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(2) Remove the seal from the plenum flange above
the air inlet duct.
INSTALLATION
NOTE: Seal should not be touching the plenum baf-
fle flange seal.
(1) Position the seal on the plenum flange and seat
fully.(2) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
COWL/PLENUM WINDOW
BAFFLE SEAL
REMOVAL
(1) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(2) Remove the seal from the window below the
cowl/plenum seal.
INSTALLATION
(1) Position the seal against the upper flange of
the inner plenum window below the cowl/plenum seal
and seat fully.
(2) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
KJWEATHERSTRIP/SEALS 23 - 187
WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER (Continued)

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

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)

(1) Connect a tachometer a manifold gauge set or
A/C recycling/charging station.
(2) Set the A/C Heater mode control switch knob in
the Recirculation Mode position, the temperature
control knob in the full cool position, and the blower
motor switch knob in the highest speed position.
(3) Start the engine and hold the idle at 1,000 rpm
with the compressor clutch engaged.
(4) The engine should be at operating temperature.
The doors and windows must be closed.
(5) Insert a thermometer in the driver side center
A/C (panel) outlet. Operate the engine for five min-
utes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity. If the
clutch cycles, unplug the a/c low pressure switch wire
harness connector. (Fig. 2). Place a jumper wire
across the terminals of the a/c low pressure switch
wire harness connector.
(7) With the compressor clutch engaged, record the
discharge air temperature and the compressor dis-
charge pressure.
(8) Compare the discharge air temperature to the
Performance Temperature and Pressure chart. If the
discharge air temperature is high, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - SPECIFICATIONS -
CHARGE CAPACITY).
Performance Temperature and Pressure
Ambient Air
Temperature21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Air Temperature at
Center Panel Outlet7É C
(45É F)7É C
(45É F)13É C
(55É F)13É C
(55É F)18É C
(64É F)
Compressor Inlet
Pressure at Service
Port (low Side)138 to 207 kPa
(20 to 30 psi)172 to 241
kPa
(25 to 35 psi)207 to 276
kPa
(30 to 40 psi)241 to 310
kPa
(35 to 45 psi)276 to 345 kPa
(40 to 50 psi)
Condensor Out
Pressuree at Service
POrt (High Side)1034 to 1724
kPa
(150 to 250
psi)1379 to 2068
kPa
(200 to 300
psi)1724 to 2413
kPa
(250 to 350
psi)1999 to 2689
kPa
(290 to 390
psi)2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor discharge pressure to
the Performance Temperature and Pressure chart. If
the compressor discharge pressure is high, see the
Pressure Diagnosis chart.
Fig. 2 A/C LOW PRESSURE SWITCH - TYPICAL
1 - A/C LOW PRESSURE SWITCH
2 - ACCUMULATOR
KJHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)

Pressure Diagnosis
Condition Possible Causes Correction
Rapid compressor clutch
cycling (ten or more cycles
per minute).1. Low refrigerant system
charge.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
Equal pressures, but the
compressor clutch does not
engage.1. No refrigerant in the
refrigerant system.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty a/c compressor
clutch coil.3. See A/C Compressor/Diagnosis and Testing -
Compressor Clutch Coil in this group. Test the
compressor clutch coil and replace, if required.
4. Faulty a/c compressor
clutch relay.4. See A/C Compressor Clutch Relay/Diagnosis
and Testing - Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty a/c low pressure
switch.5. See A/C Low Pressure Switch/Diagnosis and
Testing in this group. Test the a/c low pressure
switch and tighten or replace, if required.
6. Faulty a/c high pressure
switch.6. See A/C High Pressure Switch/Diagnosis and
Testing in this group. Test the a/c high pressure
switch and replace, if required.
7. Faulty Powertrain Control
Module (PCM).7. (Refer to Appropriate Diagnostic Information).
Test the PCM and replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.1. Excessive refrigerant oil in
system.1. See Refrigerant Oil/Standard Procedure -
Refrigerant Oil Level in this group. Recover the
refrigerant from the refrigerant system and
inspect the refrigerant oil content. Restore the
refrigerant oil to the proper level, if required.
2. Blend door inoperative or
sealing improperly.2. See Blend Door in this group. Inspect the
blend door for proper operation and sealing and
correct, if required.
3. Blend door actuator faulty
or inoperative.3. Perform blend door actuator diagnosis, replace
if faulty.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.1. Low refrigerant system
charge.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
2. Refrigerant flow through
the accumulator is restricted.2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.3. See A/C Evaporator in this group. Replace the
restricted evaporator coil, if required.
24 - 4 HEATING & AIR CONDITIONINGKJ
HEATING & AIR CONDITIONING (Continued)