2002 JEEP LIBERTY relay

INSTALLATION
2.4L 4±Cylinder
(1) Position starter into bellhousing and install 2
bolts. Refer to torque specifications.
(2) Install battery cable and nut to stud on starter
solenoid. Refer to torque specifications.
(3) Install solenoid wire connector to solenoid ter-
minal.
(4) Lower vehicle.
(5) Connect negative battery cable.
3.7L V-6
(1) Position front of starter towards rear of vehicle
with solenoid position rotated until it is located below
starter. Install starter by passing it between exhaust
pipe and transmission bellhousing.
(2) Position starter into bellhousing and install 2
bolts. Refer to torque specifications.
(3) Install battery cable and nut to stud on starter
solenoid. Refer to torque specifications.
(4) Install solenoid wire connector to solenoid ter-
minal.
(5) Position starter heat shield and install nut at
front of starter.
(6) Install 2 starter heat shield bolts at side of
starter.
(7) Install front propeller shaft.
(8) Install 2 flange bolts securing left exhaust
downpipe to crossover pipe.
(9) Lower vehicle.
(10) Connect negative battery cable.
STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when ignition switch is turned to
Start position. The starter relay is located in the
Power Distribution Center (PDC) in the engine com-
partment. See PDC cover for relay identification and
location.
The starter relay is a International Standards
Organization (ISO) relay. Relays conforming to ISO
specifications have common physical dimensions, cur-
rent capacities, terminal patterns, and terminal func-
tions.
The starter relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
Fig. 11 STARTER ELECTRICAL CONNECTORS -
2.4L/3.7L
1 - BATERY CABLE NUT
2 - BATTERY CABLE
3 - SOLENOID CONNECTOR
4 - HEAT SHIELD
Fig. 12 STARTER - 3.7L
1-STARTER
2 - MOUNTING BOLTS (2)
KJSTARTING SYSTEM 8F - 41
STARTER MOTOR (Continued)

OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When electro-
magnetic coil is energized, it draws the movable con-
tact away from normally closed fixed contact, and
holds it against the other (normally open) fixed con-
tact.
When electromagnetic coil is de-energized, spring
pressure returns movable contact to normally closed
position. The resistor or diode is connected in parallel
with electromagnetic coil within relay, and helps to
dissipate voltage spikes produced when coil is de-en-
ergized.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter relay is located in the Power Distribu-
tion Center (PDC) in engine compartment. Refer to
label on PDC cover for relay location.
RELAY TEST
(1) Remove starter relay (Fig. 13) from PDC.
(2) A relay in de-energized position should have
continuity between terminals 87A and 30, and no
continuity between terminals 87 and 30. If OK, go to
Step 3. If not OK, replace faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform following Relay Circuit Test.
If not OK, replace faulty relay.
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair open cir-
cuit to fused B(+) fuse in PDC as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to common feed terminal (30) in energized
position. This terminal supplies battery voltage to
starter solenoid field coil. There should be continuity
between cavity for relay terminal 87 and starter sole-
noid terminal at all times. If OK, go to Step 4. If not
OK, repair open engine starter motor relay output
circuit to starter solenoid as required.
(4) The coil battery terminal (86) is connected to
electromagnet in relay. It is energized when ignition
switch is held in Start position. On vehicles with amanual transmission, the clutch pedal must be
blocked in fully depressed position for this test.
Check for battery voltage at cavity for relay terminal
86 with ignition switch in Start position, and no volt-
age when ignition switch is released to On position.
If OK, go to Step 5. If not OK with a manual trans-
mission, disconnect clutch pedal position switch wire
harness connector and install a jumper wire between
two cavities in body half of connector and check for
battery voltage again at cavity for relay terminal 86.
If now OK, replace faulty clutch pedal position
switch. If still not OK with a manual transmission or
if not OK with an automatic transmission, check for
open or shorted fused ignition switch output (start)
circuit to ignition switch and repair as required. If
fused ignition switch output (start) circuit is OK,
refer toIgnition Switch and Key Lock Cylinder.
(5) The coil ground terminal (85) is connected to
electromagnet in relay. On vehicles with manual
transmission, it is grounded at all times. On vehicles
with automatic transmission, it is grounded through
park/neutral position switch only when gearshift
selector lever is in Park or Neutral positions. Check
for continuity to ground at cavity for relay terminal
85. If not OK with a manual transmission, repair
open park/neutral position switch sense circuit to
ground as required. If not OK with an automatic
transmission, check for open or shorted park/neutral
position switch sense circuit to park/neutral position
switch and repair, as required. If park/neutral posi-
tion switch sense circuit checks OK, refer toPark/
Neutral Position Switch.
Fig. 13 STARTER RELAY (ISO MICRO RELAY)
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8F - 42 STARTING SYSTEMKJ
STARTER MOTOR RELAY (Continued)

REMOVAL
The starter relay is located in the Power Distribu-
tion Center (PDC) (Fig. 14). Refer to label on PDC
cover for relay location.(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
(1) Refer to Power Distribution Center (PDC) cover
for starter relay location.
(2) Install relay to PDC.
(3) Install cover to PDC.
Fig. 14 POWER DISTRIBUTION CENTER (PDC)
1 - BATTERY
2 - PDC
3 - PDC COVER
KJSTARTING SYSTEM 8F - 43
STARTER MOTOR RELAY (Continued)

HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED MIRRORS......................... 1
WINDOW DEFOGGER....................... 3HEATED SEAT SYSTEM.................... 10
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................1
OPERATION............................1DIAGNOSIS AND TESTING - HEATED
MIRRORS............................1
HEATED MIRRORS
DESCRIPTION
Vehicles equipped with the optional heated mirror
package have an electric heating grid located behind
the mirror glass of each outside rear view mirror.
The heated mirrors are controlled by the rear win-
dow defogger switch. Electrical current is directed to
the heating grid inside the mirror only when the rear
window defogger switch is in the On position.
If the outside mirror heating grids and the rear
window heating grid are all inoperative, (Refer to 8 -
ELECTRICAL/HEATED GLASS - DIAGNOSIS AND
TESTING). If the outside mirror heating grids are
inoperative, but the rear window heating grid is
operating as designed, (Refer to 8 - ELECTRICAL/
HEATED MIRRORS - DIAGNOSIS AND TESTING).
The heating grid behind each outside mirror glass
cannot be repaired and, if faulty or damaged, the
entire power mirror unit must be replaced(Refer to 8
- ELECTRICAL/POWER MIRRORS/SIDEVIEW MIR-
ROR - REMOVAL) and (Refer to 8 - ELECTRICAL/
POWER MIRRORS/SIDEVIEW MIRROR -
INSTALLATION).
OPERATION
The heated mirror is controlled by the rear window
defogger switch. The only time that the heated mir-
ror is on is when the rear window defogger is on. The
mirror should become warm to the touch.
DIAGNOSIS AND TESTING - HEATED MIRRORS
For circuit descriptions and diagrams (Refer to
Appropriate Wiring Information).
(1) Check the fuse in the junction block. If OK, go
to Step 2. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fuse in the junction
block. If OK, go to Step 3. If not OK, repair the open
circuit to the ignition switch as required.
(3) Disconnect and isolate the battery negative
cable. Remove the front door trim panel on the side
of the vehicle with the inoperative mirror heating
grid. Unplug the wire harness connector at the mir-
ror. Check for continuity between the ground circuit
cavity in the body half of the power mirror wire har-
ness connector and a good ground. If OK, go to Step
4. If not OK, repair the open circuit to ground as
required.
(4) Connect the battery negative cable. Turn the
ignition switch to the On position. Turn on the rear
window defogger system. Check for battery voltage at
the rear window defogger relay output circuit cavity
in the body half of the power mirror wire harness
connector. If OK, go to Step 5. If not OK, repair the
open circuit to the rear window defogger relay as
required.
KJHEATED SYSTEMS 8G - 1

(5) Check for continuity between the ground cir-
cuit and the rear window defogger relay output cir-
cuit cavities in the mirror half of the power mirror
wire harness connector. There should be continuity. If
not OK, replace the faulty power mirror(Refer to 8 -
ELECTRICAL/POWER MIRRORS/SIDEVIEW MIR-
ROR - REMOVAL) and (Refer to 8 - ELECTRICAL/
POWER MIRRORS/SIDEVIEW MIRROR -
INSTALLATION). If OK, check the resistancethrough the electric heating grid circuit. Correct
resistance through the electric heating grid should be
from 10 to 16 ohms when measured at an ambient
temperature of 21É C (70É F). If not OK, replace the
faulty power mirror(Refer to 8 - ELECTRICAL/
POWER MIRRORS/SIDEVIEW MIRROR -
REMOVAL) and (Refer to 8 - ELECTRICAL/POWER
MIRRORS/SIDEVIEW MIRROR - INSTALLATION).
8G - 2 HEATED MIRRORSKJ
HEATED MIRRORS (Continued)

WINDOW DEFOGGER
TABLE OF CONTENTS
page page
WINDOW DEFOGGER
DESCRIPTION - REAR WINDOW DEFOGGER . . 3
OPERATION - REAR WINDOW DEFOGGER....3
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM...................4
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR.................4
REAR WINDOW DEFOGGER GRID
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER GRID......................5
REAR WINDOW DEFOGGER RELAY
DESCRIPTION..........................6
OPERATION............................6DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER RELAY.....................6
REMOVAL.............................7
INSTALLATION..........................7
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION..........................8
OPERATION............................8
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REAR
WINDOW DEFOGGER SWITCH...........8
DIAGNOSIS AND TESTING - REAR HVAC
CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION.................9
REMOVAL.............................9
INSTALLATION..........................9
WINDOW DEFOGGER
DESCRIPTION - REAR WINDOW DEFOGGER
The rear window defogger system will only operate
when the ignition switch is in the run position. When
the defogger switch is in the run position, an electric
heater grid on the rear window glass is energized.
Vehicles with the heated mirror options also have
heater grids located behind the outside rear view
mirror glass. Each of these grids produce heat to help
clear the rear window glass and outside rear view
mirrors of ice, snow, or fog.
OPERATION - REAR WINDOW DEFOGGER
The rear window defogger system is controlled by a
switch installed with the HVAC control assembly. An
amber indicator lamp in the switch button will light
to indicate when the rear window defogger system is
turned on. The HVAC control head circuitry, which
contains the defogger system timer logic, monitors
the state of the defogger switch through a hard-wired
input. The instrument cluster circuitry controls therear window defogger system through a hard-wired
control output to the rear window defogger relay. The
rear window defogger timer and logic circuitry cannot
be adjusted or repaired and, if faulty or damaged, the
HVAC control head assembly must be replaced.
The rear window defogger system will be automat-
ically turned off after a programmed time interval of
about ten minutes. After the initial time interval has
expired, if the rear window defogger switch is turned
on again during the same ignition cycle, the defogger
system will automatically turn off after about five
minutes.
The rear window defogger system will automati-
cally shut off if the ignition switch is turned to the
Off position, or it can be turned off manually by
depressing the instrument panel switch. Following
are general descriptions of the major components in
the rear window defogger system. Refer to the own-
er's manual in the vehicle glove box for more infor-
mation on the features, use and operation of the
defogger system.
KJWINDOW DEFOGGER 8G - 3

DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). The operation of
the electrically heated rear window defogger system
can be confirmed in one of the following manners:
²Turn the ignition switch to the run position.
²Set the defogger switch in the run position. The
rear window defogger operation can be checked by
feeling the rear window or outside rear view mirror
glass. A distinct difference in temperature between
the grid lines and the adjacent clear glass or the mir-
ror glass can be detected within three to four min-
utes of operation.
²Using a 12-volt DC voltmeter, contact the rear
glass heating grid terminal B (right side) with the
negative lead, and terminal A (left side) with the pos-
itive lead (Fig. 1). The voltmeter should read battery
voltage.
The above checks will confirm system operation.
Illumination of the defogger switch indicator lamp
means that there is electrical current available at the
output of the defogger relay, but does not confirmthat the electrical current is reaching the rear glass
heating grid lines.
If the defogger system does not operate, the prob-
lem should be isolated in the following manner:
(1) Confirm that the ignition switch is in the run
position.
(2) Ensure that the rear glass heating grid feed
and ground wires are connected to the glass. Confirm
that the ground wire has continuity to ground.
(3) Check the fuses in the Power Distribution Cen-
ter (PDC) and in the junction block. The fuses must
be tight in their receptacles and all electrical connec-
tions must be secure.
When the above steps have been completed and the
rear glass or outside rear view mirror heating grid is
still inoperative, one or more of the following is
faulty:
²Defogger switch
²Defogger relay
²HVAC control head circuitry
²Rear window grid lines (all grid lines would
have to be broken or one of the feed wires discon-
nected for the entire system to be inoperative)
²Outside rear view mirror heating grid.
If setting the defogger switch to the On position
produces a severe voltmeter deflection, check for a
short circuit between the defogger relay output and
the rear glass or outside rear view mirror heating
grids.
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR
Repair of the rear glass heating grid lines, bus
bars, terminals or pigtail wires can be accomplished
using a Mopar Rear Window Defogger Repair Kit
(Part Number 4267922) or equivalent.
WARNING: MATERIALS CONTAINED IN THE REPAIR
KIT MAY CAUSE SKIN OR EYE IRRITATION. THE
KIT CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Mask the repair area so that the conductive
epoxy can be applied neatly. Extend the epoxy appli-
cation onto the grid line or the bus bar on each side
of the break (Fig. 2).
Fig. 1 REAR WINDOW DEFOGGER
1 - DEFOGGER BACKGLASS
2 - HEATED GLASS CONNECTOR9A9
3 - HINDGE MOUNTING SCREWS (2)
4 - HINDGE (LEFT SIDE)
5 - HINDGE MOUNTING SCREWS (2)
6 - HINDGE (RIGHT SIDE)
7 - HEATED GLASS CONNECTOR9B9
8 - BACKGLASS DEFOGGER GRID
8G - 4 WINDOW DEFOGGERKJ
WINDOW DEFOGGER (Continued)

(2) Follow the instructions in the repair kit for
preparing the damaged area.
(3) Remove the package separator clamp and mix
the two conductive epoxy components thoroughly
within the packaging. Fold the package in half and
cut the center corner to dispense the epoxy.
(4) For grid line repairs, mask the area to be
repaired with masking tape or a template.
(5) Apply the epoxy through the slit in the mask-
ing tape or template. Overlap both ends of the break
by at least 19 millimeters (0.75 inch).
(6) For a terminal or pigtail wire replacement,
mask the adjacent areas so the epoxy can be
extended onto the adjacent grid line as well as the
bus bar. Apply a thin layer of epoxy to the area
where the terminal or pigtail wire was fastened and
onto the adjacent grid line.
(7) Apply a thin layer of conductive epoxy to the
terminal or bare wire end of the pigtail and place it
in the proper location on the bus bar. To prevent the
terminal or pigtail wire from moving while the epoxy
is curing, it must be wedged or clamped.
(8)
Carefully remove the masking tape or template.
CAUTION: Do not allow the glass surface to exceed
204É C (400É F) or the glass may fracture.
(9) Allow the epoxy to cure 24 hours at room tem-
perature, or use a heat gun that will not over heat
the glass. Hold the heat gun approximately 25.4 cen-
timeters (10 inches) from the repair.
(10) After the conductive epoxy is properly cured,
remove the wedge or clamp from the terminal or pig-
tail wire. Do not attach the wire harness connectors
until the curing process is complete.
(11) Check the operation of the rear window defog-
ger glass heating grid.
REAR WINDOW DEFOGGER
GRID
DESCRIPTION
The heated rear window glass has two electrically
conductive vertical bus bars and a series of 11 hori-
zontal grid lines made of a silver-ceramic material,
which is baked on and bonded to the inside surface of
the glass. The grid lines and bus bars comprise a
parallel electrical circuit.
OPERATION
When the rear window defogger switch is placed in
the On position, electrical current is directed to the
rear window grid lines through the bus bars. The
grid lines heat the rear window to clear the surface
of fog or snow. Protection for the heated grid circuit
is provided by a fuse in the Power Distribution Cen-
ter (PDC).
The grid lines and bus bars are highly resistant to
abrasion. However, it is possible for an open circuit
to occur in an individual grid line, resulting in no
current flow through the line.
The grid lines can be damaged or scraped off with
sharp instruments. Care should be taken when clean-
ing the glass or removing foreign materials, decals,
or stickers from the glass. Normal glass cleaning sol-
vents or hot water used with rags or toweling is rec-
ommended.
A repair kit is available to repair the grid lines and
bus bars, or to reinstall the heated glass pigtail
wires.
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER GRID
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). To detect breaks in
the grid lines, the following procedure is required:
(1) Turn the ignition switch to the run position.
Set the defogger switch in the On position. The indi-
cator lamp should light. If OK, go to Step 2. If not
OK, (Refer to 8 - ELECTRICAL/HEATED GLASS/
REAR WINDOW DEFOGGER RELAY - DIAGNOSIS
AND TESTING)
(2) Using a 12-volt DC voltmeter, contact the ver-
tical bus bar on the right side of the vehicle with the
negative lead. With the positive lead, contact the ver-
tical bus bar on the left side of the vehicle. The volt-
meter should read battery voltage. If OK, go to Step
3. If not OK, repair the open circuit to the defogger
relay as required.
(3) With the negative lead of the voltmeter, contact
a good body ground point. The voltage reading should
not change. If OK, go to Step 4. If not OK, repair the
circuit to ground as required.
Fig. 2 GRID LINE REPAIR
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
KJWINDOW DEFOGGER 8G - 5
WINDOW DEFOGGER (Continued)