2002 JEEP LIBERTY front panel

STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM....................1DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE........3
COLUMN...............................5
GEAR.................................13
LINKAGE..............................16
PUMP.................................17
STEERING
DESCRIPTION
Power steering systems consist of:
²Steering column & Intermediate Shaft
²Rack and pinion steering gear
²Belt driven hydraulic steering pump
²Pump pressure, supply and return hoses
²Oil Cooler
OPERATION
The steering column intermediate shaft attaches
the steering column to the gear pinion. The rotation
of the pinion moves the gear rack from side-to-side.
This lateral action of the rack pushes and pulls the
tie rods to change the direction of the front wheels.
Power assist is provided by an engine mounted
hydraulic pump. The pump supplies hydraulic fluid
to the steering gear. All vehicles are equipped with
an oil cooler.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
STEERING NOISE
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill/parking, or when the steering is at the end of it's travel. Hiss is a high frequency noise similar to that
of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing through
an orifice. There is no relationship between this noise and steering performance.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash panel
seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Loose or damaged intermediate shaft or
column.4. Inspect and repair or replace.
MOAN Pressure hose in contact with other
components.Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
KJSTEERING 19 - 1

KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is integral to the igni-
tion switch, which is mounted on the left side of the
steering column, opposite the ignition lock cylinder.
It closes a path to ground for the instrument cluster
chime warning circuitry when the ignition key is
inserted in the ignition lock cylinder and the driver
door jamb switch is closed (driver door is open). The
key-in ignition switch opens the ground path when
the key is removed from the ignition lock cylinder.
The key-in ignition switch cannot be repaired and,
if faulty or damaged, the entire ignition switch must
be replaced. (Refer to 19 - STEERING/COLUMN/IG-
NITION SWITCH - REMOVAL).
DIAGNOSIS AND TESTING - KEY-IN IGNITION
SWITCH
For circuit descriptions and diagrams, Refer to the
appropriate sections on the individual components.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Remove the steering column shrouds. Unplug
the key-in ignition switch wire harness connector
from the ignition switch.
(2) Check for continuity between the key-in switch
sense circuit and the left front door jamb switch
sense circuit terminals of the key-in ignition switch.
There should be continuity with the key in the igni-
tion lock cylinder, and no continuity with the key
removed from the ignition lock cylinder. If OK, go to
Step 3. If not OK, replace the faulty ignition switch
assembly.
(3) Check for continuity between the left front door
jamb switch sense circuit cavity of the key-in ignition
switch wire harness connector and a good ground.
There should be continuity with the driver door open,
and no continuity with the driver door closed. If OK,
see the diagnosis for Instrument Cluster in this
group. If not OK, repair the circuit to the driver door
jamb switch as required.
LOCK CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) If equipped with an automatic transmission,
place shifter in PARK position.
(2) Remove the lower shroud cover.
(3) Remove the remote keyless entry (R.K.E.) mod-
ule.
(4) Remove the halo ring around the lock cylinder.
(5) Rotate key to ON position.
(6) A release tang is located on bottom of key cyl-
inder (Fig. 10).
(7) Position a small screwdriver or pin punch into
tang access hole on bottom of steering column (Fig.
11).
(8) Push the pin punch up while pulling key cylin-
der from steering column.
Fig. 10 LOCK CYLINDER RELEASE TANG
1 - Lock Cylinder
2 - Release Tang
19 - 10 COLUMNKJ

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................3
STANDARD PROCEDURE - HEAT STAKING . . 3
SPECIFICATIONS........................4
SPECIAL TOOLS
BODY...............................5BODY STRUCTURE.......................6
HOOD................................119
DOOR - FRONT........................121
DOORS - REAR........................128
SWING GATE..........................135
EXTERIOR............................140
INSTRUMENT PANEL....................147
INTERIOR.............................156
PAINT................................162
SEATS...............................164
STATIONARY GLASS....................172
SUNROOF.............................175
WEATHERSTRIP/SEALS..................185
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
²USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL±BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DaimlerChrysler Corporation uses many different
types of push-in fasteners to secure the interior and
exterior trim to the body. Most of these fasteners can
be reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component being
removed. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
KJBODY 23 - 1

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
23 - 2 BODYKJ
BODY (Continued)

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
FENDER BOLTS 12 9 Ð
FLIP-UP GLASS HINGE BOLTS 7 Ð 60
FRONT DOOR CHECK STRAP NUTS 12 9 Ð
FRONT DOOR CHECK STRAP TO A-PILLAR BOLTS 12 9 Ð
FRONT DOOR GLASS RUN CHANNEL BOLTS 9 Ð 80
FRONT DOOR HINGE TO A-PILLAR BOLTS 28 21 Ð
FRONT DOOR HINGE TO DOOR NUTS 23 17 Ð
FRONT DOOR LATCH SCREW 11 8 Ð
FRONT DOOR LATCH STRIKER SCREWS 28 21 Ð
FRONT DOOR OUTSIDE HANDLE NUTS 6 Ð 55
FRONT DOOR REGULATOR BOLTS 9 Ð 80
FRONT SEAT BACK RECLINER BOLTS 28 21 Ð
FRONT SEAT BOLTS/NUT 43 32 Ð
FRONT SEAT RISER BOLTS 28 21 Ð
FRONT SEAT TRACK BOLTS 28 21 Ð
HOOD HINGE TO BODY BOLTS 28 21 Ð
HOOD HINGE TO HOOD BOLTS 12 9 Ð
HOOD LATCH NUTS 12 9 Ð
HOOD LATCH SUPPORT BOLTS 10 Ð 85
INSTRUMENT PANEL CENTER SUPPORT BRACKET
BOLTS23 17 Ð
INSTRUMENT PANEL HVAC NUTS/BOLTS 6 Ð 55
INSTRUMENT PANEL ROLL DOWN BOLTS 54 40 Ð
INSTRUMENT PANEL TOP BOLTS 28 21 Ð
OUTSIDE MIRROR NUTS 7 Ð 65
RADIATOR CROSSMEMBER BOLTS 12 9 Ð
REAR DOOR CHECK STRAP NUTS 12 9 Ð
REAR DOOR CHECK STRAP TO A-PILLAR BOLTS 12 9 Ð
REAR DOOR GLASS RUN CHANNEL BOLTS 9 Ð 80
REAR DOOR HINGE TO B-PILLAR BOLTS 28 21 Ð
REAR DOOR HINGE TO DOOR NUTS 23 17 Ð
REAR DOOR LATCH SCREW 11 8 Ð
REAR DOOR LATCH STRIKER SCREWS 28 21 Ð
REAR DOOR OUTSIDE HANDLE NUTS 6 Ð 55
REAR SEAT BACK HINGE BOLTS 28 21 Ð
REAR SEAT LATCH/LOCK ASSEMBLY BOLTS 28 21 Ð
REAR SEAT OUTBOARD NUTS 43 32 Ð
REAR SEAT OUTER SEAT CUSHION LEG BOLTS 35 26 Ð
ROOF RACK BOLTS 8 Ð 75
23 - 4 BODYKJ
BODY (Continued)

INDEX
DESCRIPTION FIGURE
FRONT END ASSEMBLY
INNER FRONT PANELS ( 4 )
INNER WHEELHOUSE ASSEMBLIES ( 5 )
INNER WHEEL HOUSES & LOWER REINFORCEMENTS ( 6 )
FRONT BUMPER CROSSMEMBER ASSEMBLY ( 7 )
INNER FRONT WHEELHOUSE ASSEMBLY ( 8 )
FRONT INNER RAIL ASSEMBLY ( 9 )
FRONT INNER RAILS AND BRACKET WELD POINTS ( 10 )
FRONT INNER RAILS AND BRACKET WELD POINTS ( 11 )
FRONT OUTER RAIL & TORQUE BOX ( 12 )
FRONT OUTER RAIL ASSEMBLIES ( 13 )
FRONT OUTER RAILS AND BRACKET WELD POINTS ( 14 )
INNER FRONT WHEELHOUSE ASSEMBLY - COMPLETE ( 15 )
INNER FRONT WHEELHOUSE TO RAILS ( 16 )
COWL SIDE PANEL ASSEMBLIES ( 17 )
PLENUM ASSEMBLY ( 18 )
PLENUM BAFFLE & PLENUM CLOSURE PANEL ( 19 )
PLENUM BAFFLE & STEERING COLUMN REINFORCEMENT ( 20 )
FRONT END ASSEMBLY/UNDERBODY
FLOOR PAN ASSEMBLY ( 21 )
FLOOR PAN AND DASH PANEL ( 22 )
DASH PANEL AND PLENUM ( 23 )
WHEELHOUSE, FLOOR PAN, DASH PANEL AND PLENUM ASSEMBLY ( 24 )
COWL SIDE PANEL ( 25 )
REAR FRAME RAILS
REAR FRAME RAIL ASSEMBLY ( 26 )
REAR CONTROL ARM AND SHOCK MOUNTING BRACKETS ( 27 )
REAR SPRING MOUNTING BRACKETS AND REINFORCEMENTS ( 28 )
REAR SPRING REINFORCEMENTS, SHOCK MOUNTING, FUEL PASS AND EXHAUST
HANGER BRACKET(29)
REAR WHEELHOUSE ASSEMBLIES ( 30 )
FRONT AND REAR RAIL REINFORCEMENTS ( 31 )
REAR FLOOR PAN ASSEMBLY
REAR FLOOR PAN, COMPRESSION AND ANCHOR PLATE ASSEMBLY ( 32 )
SWING GATE AND BUMPER REINFORCEMENT ( 33 )
FLOOR PAN AND REAR RAIL ASSEMBLIES ( 34 )
FLOOR PAN AND REAR RAIL ADHESIVE LOCATIONS ( 35 )
FLOOR PAN AND REAR RAIL WELD LOCATIONS ( 36 )
REAR FLOOR PAN, CROSSMEMBERS AND FUEL TANK REINFORCEMENTS ( 38 )
23 - 10 BODY STRUCTUREKJ
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

FRONT END ASSEMBLY
Fig. 4 INNER FRONT PANELS
KJBODY STRUCTURE 23 - 13
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)

Fig. 67 FRONT INNER SIDE PANELS
23 - 76 BODY STRUCTUREKJ
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)