2002 JEEP LIBERTY pan torque

(b) The sides of pump module are equipped with
tension springs (Fig. 29). These springs hold mod-
ule to bottom of fuel tank into 2 formed guides
(Fig. 30). Release module assembly from these 2
guides by sliding toward right side of fuel tank.
(c) Lift assembly from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
pump module gasket must be replaced.
(1) Position lower section of fuel pump module
assembly into fuel tank.
(2) The bottom of fuel tank has 2 formed guides.
Lock module assembly into these 2 guides by sliding
toward left side of fuel tank.
(3) Push down on plastic tab to lock module to fuel
tank guides.
(4) Connect fuel supply line to bottom of upper
pump module section.
(5) Connect fuel pressure regulator to bottom of
upper pump module section.
(6) Connect electrical connector to bottom of upper
pump module section.
(7) Position pump module into fuel tank. Notch on
module must be facing rear of tank.(8) Position lock ring to module. Tap lockring
using a brass drift and hammer (clockwise) until
rotated up to built-on stops.
(9) Attach (snap on) 2 fuel filter fuel lines to top of
fuel pump module.
(10) Connect hoses/lines to ORVR components.
(11) Fill fuel tank with fuel.
(12) Start engine and check for fuel leaks.
(13) Apply silicone sealant to bottom of fuel pump
module metal access plate.
(14) Install fuel pump module metal access plate
and 4 nuts. Tighten nuts to 3 N´m (26 in. lbs.)
torque.
(15) Position carpet and install 2 new cargo clamp
rivets into each cargo holdown clamp.
Fig. 25 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
Fig. 26 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
6 - ELECTRICAL CONNECTOR
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)
KJFUEL DELIVERY 14 - 19
FUEL PUMP MODULE (Continued)

INSTALLATION
(1) Place accelerator pedal assembly over 2 studs
(Fig. 1) protruding from floor pan.
(2) Install 2 mounting nuts. Refer to torque speci-
fications.
(3) Slide throttle cable into opening slot in top of
pedal arm.
(4) Push plastic cable retainer (clip) into accelera-
tor pedal arm opening until it snaps into place.
(5) Before starting engine, operate accelerator
pedal to check for any binding.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
2.4L
The Crankshaft Position (CKP) sensor is mounted
into the right front side of the cylinder block (Fig. 2).
It is positioned and bolted into a machined hole.
3.7L
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block (Fig. 3).
It is positioned and bolted into a machined hole.
Fig. 1 ACCELERATOR PEDAL/BRACKET ASSEMBLY
1 - METAL THROTTLE CABLE CLIP
2 - THROTTLE CABLE
3 - PLASTIC CABLE RETAINER
4 - PEDAL/BRACKET ASSEMBLY
5 - PEDAL MOUNTING NUTS (2)
6 - PEDAL MOUNTING STUDS (2)
Fig. 2 CKP SENSOR LOCATION-2.4L
1 - RIGHT FRONT ENGINE MOUNT
2 - CKP SENSOR
3 - MOUNTING BOLT
4 - ELECTRICAL CONNECTOR
Fig. 3 CKP - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
14 - 30 FUEL INJECTIONKJ
ACCELERATOR PEDAL (Continued)

INSTALLATION
(1) Align and install column into the steering cou-
pler.(2) Install column harness and connect harness to
switches.
(3) Reroute the shifter interlock cable through the
tie straps.
(4) Install the column onto the mounting studs.
(5) Install the two mounting nuts and the two
mounting bolts all finger tight.
CAUTION: Lower nuts must be installed and tight-
ened first then the upper nuts in order to prevent
damage to the capsules.
(6) Tighten the lower mounting nuts to 17 N´m
(150 in. lbs.).
(7) Tighten the upper mounting nuts to 17 N´m
(150 in. lbs.).
(8) Install the steering column coupler bolt and
tighten to 49 N´m (36 ft. lbs.).
(9) Reconnect the shifter interlock cable.
(10) Center the clock spring (if necessary) and
install it on the column, (Refer to 8 - ELECTRICAL/
RESTRAINTS/CLOCKSPRING - INSTALLATION).
(11) Snap together the column shrouds and install
the mounting screws.
(12) Install the knee blocker and the knee blocker
cover, (Refer to 23 - BODY/INSTRUMENT PANEL/
KNEE BLOCKER - INSTALLATION).
(13)
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.Install the
steering wheel and tighten bolt to 54 N´m (40 ft.
lbs.) (Refer to 19 - STEERING/COLUMN/STEERING
WHEEL - INSTALLATION).
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(14) Install the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(15) Install the negative battery terminal.
Fig. 5 WIRING HARNESS COLUMN
1 - Column Wiring Harness
2 - Multi-function Switch
3 - Ignition Switch
4 - Steering Column
Fig. 6 CLOCK SPRING
1 - Tilt Lever
2 - Ignition Switch
3 - Clockspring
4 - Steering Column
5 - SKIM
KJCOLUMN 19 - 7
COLUMN (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)

(4) Test sunroof operation, adjust as necessary.
(5) Install headliner. (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION)
CONTROL MODULE
REMOVAL
(1) Remove the module assembly. (Refer to 23 -
BODY/SUNROOF/MODULE ASSEMBLY -
REMOVAL)
(2) Remove three motor assembly retaining screws
from bottom side of motor, and remove motor assem-
bly (Fig. 11).
(3) From top side of module assembly, remove one
attaching screw from electronics module. (Fig. 12)
(4) Remove old timing module.
INSTALLATION
(1) Check glass assembly position. Adjust to full
closed position. Insert pin into holes in lift arm
assembly to check position (Fig. 13).
(2) Set new electronic module in position on top
side of motor mounting bracket engaging drive cables
with pinion gear in electronics module.
(3) Install one screw to attach electronics module
to motor bracket. Tighten screw to 3 N´m (27 in. lbs.)
torque.
(4) Install motor assembly to motor bracket and
electronics module with three screws. Tighten screw
to 1.75 N´m (15.5 in. lbs.) torque.
(5) Remove the new module's timing pin and dis-
card. (Fig. 14)(6) Connect electrical connector to module assem-
bly wire harness. Secure any loose wires.
(7) Install module assembly. (Refer to 23 - BODY/
SUNROOF/MODULE ASSEMBLY - INSTALLA-
TION)
(8) Test operation, adjust as necessary. (Refer to 23
- BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS)
(9) Install opening trim lace. (Refer to 23 - BODY/
SUNROOF/OPENING TRIM LACE - INSTALLA-
TION)
Fig. 12 CONTROL MODULE
1 - MOTOR BRACKET
2 - CABLES
3 - SCREW
4 - CONTROL MODULE
Fig. 13 LIFT ARM POSITIONING
1 - GLASS BRACKET
2 - LIFT ARM
3 - ALIGNMENT PIN
Fig. 14 MODULE TIMING PIN
1 - CONTROL MODULE
2 - TIMING PIN
KJSUNROOF 23 - 183
DRIVE MOTOR (Continued)

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
A/C COMPRESSOR CLUTCH PLATE NUT 14.4 10.5 127.4
A/C COMPRESOR LINE MANIFOLD FASTENER 28 ( 6) 21 ( 4) 250 ( 50)
A/C COMPRESSOR TO MOUNTING BRACKET
BOLTS - 3.7L and 2.4L27 20 239
A/C COMPRESSOR TO MOUNTING BRACKET
BOLTS - 2.5L DIESEL33 25 292
ACCUMULATOR RETAINING BAND 5 3.7 44
BLEND DOOR ACTUATOR SCREWS 2.4 ( .34) 1.8 ( .25) 21 ( 3)
HVAC HOUSING SCREWS 2.4 ( .34) 1.8 ( .25) 21 ( 3)
HVAC HOUSING TO DASH PANEL NUTS 6.2 4.6 55
SUCTION LINE TO ACCUMULATOR FITTING 9 6.6 80
24 - 10 HEATING & AIR CONDITIONINGKJ
HEATING & AIR CONDITIONING (Continued)

to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, rotor, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Unplug the compressor clutch coil wire harness
connector.
(4) Remove the four bolts that secure the compres-
sor to the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
(6) Insert the two pins of the spanner wrench
(Special Tool C-4489 or equivalent) into the holes of
the clutch plate. Hold the clutch plate stationary and
remove the hex nut (Fig. 2).(7) Remove the clutch plate.
(8) Remove the compressor clutch shims.
(9) Remove the external front housing snap ring
with snap ring pliers (Fig. 3).
(10) Install the lip of the rotor puller (Special Tool
C-6141-1 or equivalent) into the snap ring groove
exposed in the previous step, and install the shaft
protector (Special Tool C-6141-2 or equivalent) (Fig.
4).
Fig. 2 CLUTCH NUT REMOVE
1 - CLUTCH PLATE
2 - SPANNER
Fig. 3 EXTERNAL SNAP RING REMOVE
1 - PULLEY
2 - SNAP RING PLIERS
Fig. 4 SHAFT PROTECTOR AND PULLER
1 - PULLER JAW
2 - SHAFT PROTECTOR
KJCONTROLS 24 - 13
A/C COMPRESSOR CLUTCH (Continued)