2002 JEEP LIBERTY vent

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

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................175
DIAGNOSIS AND TESTING
WATER DRAINAGE AND WIND NOISE
DIAGNOSIS.........................176
DIAGNOSTIC PROCEDURES...........176
GLASS PANEL
REMOVAL............................178
INSTALLATION........................178
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 178
GLASS PANEL SEAL
REMOVAL............................178
INSTALLATION........................178
SUNSHADE
REMOVAL............................179
INSTALLATION........................179
GUIDE ASSEMBLY
REMOVAL............................179
INSTALLATION........................179
WIND DEFLECTOR
REMOVAL............................180INSTALLATION........................180
OPENING TRIM LACE
REMOVAL............................180
INSTALLATION........................180
DRAIN TUBE
REMOVAL............................180
INSTALLATION........................181
MODULE ASSEMBLY
REMOVAL............................181
INSTALLATION........................181
DRIVE MOTOR
REMOVAL............................182
INSTALLATION........................182
CONTROL MODULE
REMOVAL............................183
INSTALLATION........................183
CONTROL SWITCH
DESCRIPTION........................184
OPERATION..........................184
DIAGNOSIS AND TESTING...............184
REMOVAL............................184
INSTALLATION........................184
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sunroof features a power sliding glass panel
and a sunshade which can be manually positioned
anywhere along its travel, rearward of glass panel
front edge.
The sunroof is electrically operated from two
switches located on the windshield header, rearwardof the map lamp. To operate the sunroof the ignition
switch must be in either the Accessory or On/Run
position. One switch (vent) is a push button type and
opens the sunroof to the vent position only. The other
switch (open/close) is a rocker type for opening and
closing the sunroof. Pressing and releasing the open
button once the sunroof will express open and the
wind deflector will raise. If the button is pressed a
second time the sunroof will stop in that position.
Pressing and holding the close button will close the
sunroof. If the close button is released the sunroof
will stop in that position.
KJSUNROOF 23 - 175

SUNROOF OPERATION INSTRUCTIONS
SWITCH INPUTS
OPEN CLOSE VENT
FULL VENTPush and hold switch until
glass stops in flush closed
position glass will then
express openPush and hold switch until
glass stops in flush closed
position.No action
VENT RANGEPush and hold switch until
glass passes through
flush closed position.
Glass will then openPush and hold switch until
glass stops in flush closed
position.Push and hold switch until
glass stops in full vent
position.
FLUSH1. Press switch for less
than 0.65 seconds for
express to comfort stop.No action Press and hold switch.
Glass will travel through
flush closed to full vent.
Glass will stop when
switch is released or when
fully vented.
2. Press switch for more
than 0.65 seconds and
glass will stop when
switch is released
FULL OPENPress switch for less than
0.65 seconds for express
to full open.Press and hold switch
until glass stops in flush
closed position or
anywhere in between.Press and hold switch.
Glass will travel through
flush closed to full vent.
Glass will stop when
switch is released.
DIAGNOSIS AND TESTING
WATER DRAINAGE AND WIND NOISE
DIAGNOSIS
The sliding glass panel is designed to seal water
entry with a snug fit between the roof and the seal.
The fit can be checked by inserting a piece of paper
between the roof and the seal. The piece of paper
should have some resistance when pulled out when
the glass panel is in the closed position. The sunroof
housing will drain off a minimum amount of water.
Excessive wind noise could result if the gap clear-
ances are exceeded. The sunroof glass panel may
need to be adjusted. Refer to Sunroof Glass Panel
Adjustment for proper procedures.
Adequate drainage is provided by a drain trough in
the sunroof housing which encircles the sliding glass
panel and leads to drain hoses. If a wet headliner or
other water leak complaints are encountered, before
performing any adjustments, first ensure that the
drainage system is not plugged or disconnected. Use
a pint container to pour water into the sunroof hous-
ing drain trough. If water flow is restricted, use com-
pressed air to blow out any material plugging the
drain system. Retest system again.To further check for a disconnected drain hose:
(1) Remove A-pillar trim, sun visors, and map
lamps/mini console.
(2) Remove sunroof opening trim lace. Refer to
Sunroof Opening Trim Lace.
(3) Lower headliner as necessary to gain access to
sunroof housing drain tubes. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - REMOVAL)
(4) Repair as necessary.
DIAGNOSTIC PROCEDURES
Before beginning sunroof diagnostics verify that all
other power accessories are in proper operating condi-
tion. Refer to Sunroof Diagnostic Chart for possible
causes. If not, a common electrical problem may exist.
Refer to Wiring Diagrams, in this publication for circuit,
splice and component descriptions. Check the condition
of the circuit protection (20 amp circuit breaker in cav-
ity 19 of the Junction Block). Inspect all wiring connec-
tor pins for proper engagement and continuity. Check
for battery voltage at the power sunroof controller, refer
to Wiring Diagrams, for circuit information. If battery
voltage of more than 10 volts is detected at the control-
ler, proceed with the following tests (the controller will
not operate at less than 10 volts).
23 - 176 SUNROOFKJ
SUNROOF (Continued)

Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
SUNROOF DIAGNOSIS CHART
SYMPTOM POSSIBLE CAUSE
Sunroof motor inoperative. Faulty control switch.
Faulty circuit ground between sunroof electronics module,
control switch, and body harness.
Faulty power circuit between sunroof electronics module,
control switch, and body harness.
Faulty drive motor.
Faulty electronics module.
Faulty drive motor electrical connector.
Audible whine when switch is depressed,
sunroof does not operate.Faulty drive motor.
Binding cable.
Audible clicking or ratcheting when switch is
pressed, sunroof does not operate.Broken or worn drive cable.
Worn drive motor gear.
Mechanisms not synchronized.
Sunroof vents and opens, but does not close. Binding cable.
Faulty circuit.
Faulty control switch.
Faulty electronic module.
Faulty drive motor.
Sunroof vents, but does not open. Binding cable or mechanism.
Faulty circuit.
Faulty switch.
Faulty electronic module.
Sunroof does not vent Binding cable or mechanism.
Faulty circuit.
Faulty control switch.
Faulty sunroof electronic module.
Sunroof water leak. Drain tubes clogged or kinked or disconnected from the
sunroof.
Glass panel improperly adjusted.
Faulty glass panel seal.
Gurgling sound from sunroof Low spot in drain hose routing, allowing water to stand.
Wind noise from sunroof. Front of glass panel too high or rear too low.
Wind deflector not deploying.
Glass not centered in opening.
Faulty glass panel seal.
Rattles from open sunroof while driving Loose or broken attaching hardware.
Worn or broken mechanism.
KJSUNROOF 23 - 177
SUNROOF (Continued)

SUNSHADE
REMOVAL
(1) Remove glass assembly from the sunroof
assembly. (Refer to 23 - BODY/SUNROOF/GLASS
PANEL - REMOVAL)
(2) Remove two screws from trough assembly (Fig.
3).
(3) Remove trough assembly.
(4) Slide the sunshade forward to disengage the
guide feet from the tracks through the cutouts at the
front of the tracks.
CAUTION: Use care not to crease the sunshade
when removing or installing.
INSTALLATION
(1) Place sunshade into position, through the cut-
outs at the front of the tracks and slide the sunshade
back.
(2) Place trough assembly into position on sunroof
module and install the screws.
(3) Install the glass panel. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - INSTALLATION)
GUIDE ASSEMBLY
REMOVAL
(1) Remove the glass panel. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - REMOVAL)
(2) Place sunroof into the vent position.
(3) Remove two screws from trough assembly (Fig.
3).
(4) Remove trough assembly.
(5) Disconnect the guide link (Fig. 4).
(6) Slide trough guide forward and disengage the
sliders through the notches in the guide channels
(Fig. 5).
INSTALLATION
(1) Install the trough guide and engage the sliders
into the guide channels through the notches.
(2) Connect the guide link.
(3) Install the trough and install the two screws.
(4) Install the glass panel. (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - INSTALLATION)
Fig. 3 GUIDE ASSEMBLY TROUGH
1 - TROUGH
2 - TROUGH GUIDE
3 - SCREW
Fig. 4 TROUGH GUIDES
1 - TROUGH GUIDE
2 - GUIDE LINK
KJSUNROOF 23 - 179

(5) Connect wire harness.
(6) Install the headliner. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION)
(7) Install the opening trim lace. (Refer to 23 -
BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION)
(8) Connect battery negative cable.
(9) Test sunroof operation, adjust as necessary.
(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS)
DRIVE MOTOR
REMOVAL
(1) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(2) Cut wire retaining tape being careful not to cut
wires.
(3) Disconnect the electrical connector (Fig. 11).
(4) Remove three motor assembly attaching screws
from bottom side of motor assembly and remove
motor assembly from the motor bracket.
INSTALLATION
(1) Place motor into position and install screws
attaching motor to bracket.
NOTE: Hold electronics module to motor bracket
when inserting motor shaft to avoid disengaging
drive cables.
(2) Connect electrical connector.
(3) Tape wires to drive cables to prevent rattles.
Fig. 9 WIRE HARNESS
1 - CLIPS
2 - ELECTRICAL CONNECTOR
3 - WIRE HARNESS
Fig. 10 MODULE ASSEMBLY
1 - U-NUTS
2 - DRIVE MOTOR
3 - BOLTS
4 - GLASS OPENING
5 - MODULE ASSEMBLY
Fig. 11 DRIVE MOTOR ASSEMBLY
1 - CONTROL MODULE
2 - SCREWS
3 - DRIVE MOTOR
4 - SCREW
5 - ELECTRICAL CONNECTOR
23 - 182 SUNROOFKJ
MODULE ASSEMBLY (Continued)

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

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