JEEP LIBERTY 2002 KJ / 1.G Workshop Manual
JEEP
ž
2002
LIBERTY
SERVICE MANUAL and
2.4L GAS SUPPLEMENT
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Litho in U.S.A. Copyright 2001 DaimlerChrysler Corporation
7.5M0901
Page 2 of 1803
FOREWORD
This manual is designed as a supplement to be used along with the 2002 Liberty service manual,
81-370-02060. It includes information related to the 2.4L gas engine installed in this vehicle by
DaimlerChrysler Corporation. For diagnosis or service procedures relating to other components or systems,
refer to the 2002 Liberty Service Manual.
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
Page 3 of 1803
GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
2SSuspension
3Differential & Driveline
5Brakes
5SBrakes
6Clutch
7Cooling
7SCooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8LSLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
9SEngine
11Exhaust System
11SExhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
2.4L Gas Component and System Index
Service Manual Comment Forms
NOTE: For New Vehicle Preparation information, see the separate
publication, 81-170-00003.
NOTE: Group names with the suffix(S(indicate groups pertaining to the
the 2.4L Gas Supplement
Page 4 of 1803
INTRODUCTION
TABLE OF CONTENTS
page page
FASTENER IDENTIFICATION
DESCRIPTION. 1
FASTENER USAGE
DESCRIPTION
DESCRIPTION. 4
DESCRIPTION. 4
THREADED HOLE REPAIR
DESCRIPTION. 4
INTERNATIONAL SYMBOLS
DESCRIPTION. 4
METRIC SYSTEM
DESCRIPTION. 5TORQUE REFERENCES
DESCRIPTION. 7
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION. 8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION. 8
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION. 9
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of linemarks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 1) and (Fig. 2).
KJINTRODUCTION 1
Page 5 of 1803
Fig. 1 FASTENER IDENTIFICATION
2 INTRODUCTIONKJ
FASTENER IDENTIFICATION (Continued)
Page 6 of 1803
Fig. 2 FASTENER STRENGTH
KJINTRODUCTION 3
FASTENER IDENTIFICATION (Continued)
Page 7 of 1803
FASTENER USAGE
DESCRIPTION
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 3) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 3 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
4 INTRODUCTIONKJ
Page 8 of 1803
METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x
0.11298= Newton Meters
(N´m)N´m x 8.851 = in-lbs
ft-lbs x
1.3558= Newton Meters
(N´m)N´m x
0.7376= ft-lbs
Inches Hg (60É F) x 3.377 = Kilopascals (kPa) kPa x
0.2961= Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x
0.03937= Inches
Feet x
0.3048= Meters (M) M x 3.281 = Feet
Yards x
0.9144= Meters M x
1.0936= Yards
mph x
1.6093= Kilometers/Hr.
(Km/h)Km/h x
0.6214= mph
Feet/Sec x
0.3048= Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x
0.4470= Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x
0.27778= Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N´m).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
KJINTRODUCTION 5
Page 9 of 1803
METRIC CONVERSION CHART
6 INTRODUCTIONKJ
METRIC SYSTEM (Continued)
Page 10 of 1803
TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-tions Chart for torque references not listed in the
individual torque charts.
TORQUE SPECIFICATIONS
KJINTRODUCTION 7
2002 jeep liberty JEEP LIBERTY 2002 KJ / 1.G Workshop Manual
JEEP
ž
2002
LIBERTY
SERVICE MANUAL and
2.4L GAS SUPPLEMENT
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Litho in U.S.A. Copyright 2001 DaimlerChrysler Corporation
7.5M0901
Page 12 of 1803
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)
Page 1777 of 1803
i.»JEEP LIBERTY 2002
AIR BAGReferto Procedure Explantion 29for Supplemental RestrainVAirBag Special Cautions.
Paint code located on left Iront door jamb.
All colors are clear coat.
Label, Air Bag WarningLabel, Emission24L Eng3 7L EngLabel, Visor Air BagLabel, Side Air BagLabel, Jack Instructions
56010562M
53013384M53013387M4897875M4649282M52059412M
0.00
2.002.00.502.603.20
Use Procedure Explanations 1 and 28 with the following text.RefinishFrontCover 2.3RefinishOpeningCover R/L .2R&I BumperAssy #2.0O/H Bumper Assy (Includes R&I) #2.9#Includes fl&VR&R Grille & Wheel Opening Flares
563Procedure Explanation Pages Must Be Used with the Above Text for an Accurate Damage Report.Comments or suggestions? Need assistance? Call 1-800-854-7030 or 858/578-6550, EX! 8220. Fax 1-888-256-7969 or 858/549-0629.CH
Page 1781 of 1803
JEEP LIBERTY 2002
SPARE WHEEL & HARDWARE19-020- —E
1 b~4
~A56010126AD
m .6 75.00I56010125AD m .6 75.0056010158AC m .5 29.204793576 m.7 5.205GK59DX9AB m #.3 6.20
96.206.25
6.206.20
5.45
.2- . I-4 — :OV 6.505 Channel, Glass R 55235874AB #.9 78.50 IL 55235875AB #.9 78.50#W/Door Glass Removed Ceduct.6
R 55177040ACL 55177041ACR 55177042ACL 55177043ACRemoved
AiL 4780607AAAiL 4520289AiL N.A.Removed
R 5072350AAL 5072351AAR 55360534ABL 55360535ABR 55360332ABL 55360333ABRemoved
1 Panel, TrlmllCloth R 5GF18WL5AB .4 245.00L 5GF19WL5AB .4 245.00Leather R 5GF221D2AB .4 272.00L 5GF231D2AB .4 272.002 Plug, Door1] AiL 5GY30XDVAA .45llAdditional Parls &/or Dealer Contact Required3 Speaker. Door
Refinish Door Outside AiL 2.2AddforJambs&lnterior AiL 1.0AddforJambs AiL .5R&IDoorAssy AiL .6