2002 JEEP LIBERTY weight

VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV W/O Side Airbags.
8 = MPV With Side Airbags.
4 Gross Vehicle Weight Rating F = 4001 - 5000 lbs.
G = 5001 - 6000 lbs.
5 Vehicle Line K = Liberty 4X2 (LHD)
L = Liberty 4X4 (LHD)
M = Cherokee 4X4 (RHD)
6 Series 3 = Liberty Renegade
4 = Liberty Sport/Cherokee Sport
5 = Liberty Limited/Cherokee Limited
7 Body Style 8 = Sport Utility - 4 Door
8 Engine K = 3.7L 6 cyl MPI Gasoline
1 = 2.4L 4 cyl MPI Gasoline
7 = 2.5L 4 cyl Diesel
9 Check Digit 0 through 9 or X
10 Model Year 2=2002
11 Assembly Plant W = Toledo North Assembly Plant
12 thru 17 Vehicle Build Sequence
VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 6) is
attached to every DaimlerChrysler Corporation vehi-
cle. The label certifies that the vehicle conforms to all
applicable Federal Motor Vehicle Safety Standards.
The label also lists:
²Month and year of vehicle manufacture.
²Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) arebased on a minimum rim size and maximum cold tire
inflation pressure.
²Vehicle Identification Number (VIN).
²Type of vehicle.
²Bar code.
²Month, Day and Hour (MDH) of final assembly.
²Paint and Trim codes.
²Country of origin.
The label is located above the door hinge on the
driver-side A-pillar.
Fig. 6 Vehicle Safety Certification LabelÐTypical
KJINTRODUCTION 9
VEHICLE IDENTIFICATION NUMBER (Continued)

STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT
MEASUREMENT
RIDE HEIGHT
NOTE: The suspension is non-adjustable.
The vehicle suspension height should be measured
before performing wheel alignment procedure. Also
when front suspension components have been
replaced. This measure must be performed with the
vehicle supporting it's own weight and taken on both
sides of the vehicle.
Front and rear ride heights are not adjustable. The
spring selections at assembly determine ride height
for acceptable appearance of the vehicle. Ride height
dimensions assume full fluids (including fuel) and
zero passengers. Refer to the table below for front
ride height dimensions.
Vehicle ride height audits should be performed uti-
lizing the following procedure:
(1) Drive the vehicle straight and forward on a
non-tacky surface for a minimum of 20 feet to neu-
tralize track width.
(2) Bounce the front of the vehicle five times.
(3) Measure and record the dimensions
FRONT RIDE HEIGHT Front ride height is
defined by the relative vertical distance between the
spindle center line and the rear pivot point of the
front lower control arm to cradle attachment. The
spindle center line is to be measured at the outer
wheel face (point A). The rear pivot point is to be
measured at the center of the cam bolt (point B) at
its rearward most end (nut end). (Fig. 2)REAR RIDE HEIGHT Rear ride height is defined
by the relative vertical distance between the top of
the lower spring seat strike surface and the bottom
of the jounce cup (true metal to metal jounce travel).
This is to be measured vertically inside the coil from
the point intersecting the inboard edge and the for/
aft center of the jounce cup (point C) down to the
strike surface (point D). (Fig. 3)
Measurement Target Minimum Maximum
Front Ride
Height
Distance AB48.8 mm
Z=996.81
- 948.0338.8mm 58.8mm
Front Cross
Ride Height
Left - Right0.0 mm -10.0 mm 10.0 mm
Rear Ride
Height
Distance CD116.1 mm 106.1 mm 126.1 mm
Rear Cross
Ride Height
Left - Right0.0 mm -10.0 mm 10.0 mm
Fig. 2 FRONT RIDE HEIGHT MESUREMENT
1 - POINT - A
2 - POINT - B
Fig. 3 REAR RIDE HEIGHT MEASUREMENT
1 - POINT - C
2 - POINT - D
2 - 4 WHEEL ALIGNMENTKJ
WHEEL ALIGNMENT (Continued)

FRONT
TABLE OF CONTENTS
page page
FRONT
DESCRIPTION..........................7
WARNING.............................7
SPECIFICATIONS
TORQUE CHART......................8
SPECIAL TOOLS
FRONT SUSPENSION...................8
BUSHINGS
REMOVAL - STABILIZER BAR BUSHINGS.....9
INSTALLATION - STABILIZER BAR BUSHINGS . . 9
HUB / BEARING
REMOVAL.............................9
INSTALLATION..........................9
KNUCKLE
REMOVAL.............................9
INSTALLATION..........................9
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT..............................10
LOWER CONTROL ARM
REMOVAL.............................10
INSTALLATION.........................10
SHOCK
REMOVAL
REMOVAL - LEFT SIDE.................11REMOVAL - RIGHT SIDE................11
INSTALLATION
INSTALLATION - LEFT SIDE.............12
INSTALLATION - RIGHT SIDE............12
SPRING
REMOVAL.............................13
INSTALLATION.........................13
CLEVIS BRACKET
REMOVAL.............................13
INSTALLATION.........................13
STABILIZER BAR
REMOVAL.............................14
INSTALLATION.........................14
STABILIZER LINK
REMOVAL.............................14
INSTALLATION.........................14
UPPER CONTROL ARM
REMOVAL
REMOVAL - RIGHT SIDE................14
REMOVAL - LEFT SIDE.................15
INSTALLATION
INSTALLATION - RIGHT SIDE............15
INSTALLATION - LEFT SIDE.............15
FRONT
DESCRIPTION
The front suspension is designed to allow each
wheel to adapt to different road surfaces indepen-
dently. The wheels are mounted to hub bearings on
the steering knuckle spindles. The double-row hub
bearings are sealed and lubricated for life. The steer-
ing knuckles turn (pivot) on ball joints riveted to the
outboard portion of the control arms. The ball joints
are lubricated for life. (Fig. 1)
WARNING
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
Fig. 1 FRONT SUSPENSION
1-SWAYBAR
2 - SWAY BAR BUSHING/BRACKET
3 - UPPER CONTROL ARM
4 - SPRING / SHOCK ASSEMBLY
5 - STEERING KNUCKLE
6 - OUTER TIE ROD END
7 - LOWER CONTROL ARM
8 - SWAY BAR LINK
9 - CLEVIS BRACKET
KJFRONT 2 - 7

(5) Install the hub/bearing. (Refer to 2 - SUSPEN-
SION/FRONT/HUB / BEARING - INSTALLATION).
(6) Install the axle shaft nut. Tighten the nut to
135 N´m (96 ft.lbs.).(if equipped with four wheel
drive).
(7) Install the wheel speed sensor. (Refer to 5 -
BRAKES/ELECTRICAL/FRONT WHEEL SPEED
SENSOR - INSTALLATION).
(8) Install the disc brake rotor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(9) Install the caliper adapter. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(10) Install the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Perform the set toe procedure (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
(1) Raise the vehicle on a drive-on hoist.
NOTE: If a drive-on hoist is not available, use
wooden blocks with jack stands to support the
lower control arm in the ball joint area. Place the
jack stands appropriately and lower the hoist plac-
ing weight on the lower control arm. The lower con-
trol arms should now be supporting the vehicle
weight.
(2) With the use of jack stands, lift the front end
off the hoist and position wooden blocks underneath
both lower control arms supporting the vehicles
weight.
(3) Remove the tire and wheel assembly.
(4) Attach a dial indicator to the base of the lower
control arm and align the dial indicator's contact
point with the direction of the stud axis, touch the
machined flat on the knuckle and zero the dial indi-
cator. (Fig. 2)
NOTE: Use care when applying the load to the
knuckle, so the parts are not damaged using care
not to tear the boot.
(5) From the front of the vehicle, insert a pry bar
to get it rested on the lower control arm and use
lever principle to push the knuckle up until the arm
of the dial indicator no longer moves.(6) Record the ball joint movement on each side of
the vehicle. The end play is acceptable with no more
than 1.5mm of end play back to back.LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Remove the lower clevis bracket bolt at the
lower control arm.
(4) Remove the stabilizer link bolt at the lower
control arm.
(5) Remove the lower ball joint nut.
(6) Separate the lower ball joint from the lower
control arm using tool C-4150A.
NOTE: Marking the lower control arm pivot bolts
front and rear will aid in the assembly procedure.
(7) Mark the lower control arm pivot bolts front
and rear.
(8) Remove the front cam/pivot bolt. (Fig. 3)
(9) Remove the rear cam/pivot bolt. (Fig. 3)
(10) Remove the lower control arm from the vehi-
cle.
INSTALLATION
(1) Install the lower control arm to the vehicle.
(2) Install the rear cam/pivot bolt.
(3) Install the front cam/pivot bolt.
(4) Install the lower ball joint nut. Tighten the nut
to 81 N´m (60 ft.lbs.)
Fig. 2 SUSPENSION IN THE CURB POSITION
1-PRYBAR
2 - BALL JOINT
3 - DIAL INDICATOR
4 - WOODEN BLOCK OR SUPPORT
5 - CLAMP
2 - 10 FRONTKJ
KNUCKLE (Continued)

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION.........................16
WARNING.............................16
DIAGNOSIS AND TESTING - REAR
SUSPENSION........................17
SPECIFICATIONS
TORQUE CHART......................17
SHOCK
REMOVAL.............................18
INSTALLATION.........................18
SPRING
REMOVAL.............................18
INSTALLATION.........................18
JOUNCE BUMPER
REMOVAL.............................19
INSTALLATION.........................19
STABILIZER BAR
REMOVAL.............................19INSTALLATION.........................19
UPPER BALL JOINT
REMOVAL.............................20
INSTALLATION.........................20
UPPER CONTROL ARM
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............20
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............20
REMOVAL.............................20
INSTALLATION.........................21
LOWER CONTROL ARM
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
REAR
DESCRIPTION
The rear suspension (Fig. 1) is comprised of :
²Drive axle
²Shock absorbers
²Coil springs
²Lower suspension arms
²Upper suspension arm
²Stabilizer bar
CAUTION: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear.
WARNING
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
Fig. 1 REAR SUSPENSION
1 - COIL SPRING
2 - UPPER SUSPENSION ARM
3 - STABILIZER BAR
4 - LOWER SUSPENSION ARM
5 - SHOCK
2 - 16 REARKJ

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1. Undercoating or other foreign
material on shaft.1. Clean exterior of shaft and wash
with solvent.
2. Loose U-joint clamp screws. 2. Install new clamps and screws
and tighten to proper torque.
3. Loose or bent U-joint yoke or
excessive runout.3. Install new yoke.
4. Incorrect driveline angularity. 4. Measure and correct driveline
angles.
5. Worn joint. 5. Install new joint.
6. Propeller shaft damaged or out
of balance.6. Installl new propeller shaft.
7. Broken rear spring. 7. Install new rear spring.
8. Excessive runout or unbalanced
condition.8. Re-index propeller shaft, test, and
evaluate.
9. Excessive drive pinion gear shaft
runout.9. Re-index propeller shaft and
evaluate.
10. Excessive axle yoke deflection. 10. Inspect and replace yoke if
necessary.
11. Excessive transfer case runout. 11. Inspect and repair as necessary.
Joint Noise 1. Loose U-joint clamp screws. 1. Install new clamps and screws
and tighten to proper torque.
2. Lack of lubrication. 2. Replace joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180É relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas.If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.(9) Install a screw clamp at position 1 (Fig. 1).
Fig. 1 CLAMP AT POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFTKJ
PROPELLER SHAFT (Continued)

When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out of balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.
All driveline components should be examined
before starting any repair.
Fig. 2 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 20 FRONT AXLE - 186FIAKJ
FRONT AXLE - 186FIA (Continued)

DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged) can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
KJFRONT AXLE - 186FIA 3 - 21
FRONT AXLE - 186FIA (Continued)