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Jeep Cherokee KJ 2002-2007 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Code: KJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Sport Utility Vehicle Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester Key Features Vehicle Highlights: Renowned Jeep off-road capability in a more compact and refined package, available with multiple powertrain options. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Format: PDF Primary Audience: Mechanical Technicians 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, engine performance diagnostics Transmission Systems: Automatic Transmission (42RLE), manual transmission (NV1500/NV3500 if applicable), clutch, transfer case, driveline Brake Systems: Front and rear disc brakes, ABS, parking brake Steering Suspension: Power steering, steering gear, suspension components (front and rear), shocks, struts, springs Electrical Systems: Battery, charging system, starting system, lighting, instrumentation, body controls, comfort systems, wiring diagrams Body Chassis: Body construction, interior trim, exterior trim, doors, glass, HVAC system, frame, exhaust system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting charts Repair: Step-by-step repair procedures for all major systems, component removal and installation Diagnostics: On-Board Diagnostics (OBD-II) system information, diagnostic trouble codes (DTCs), scan tool usage Technical Depth Depth Of Information: Comprehensive; covers routine maintenance, diagnostics, component repair, and overhaul procedures. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable pages Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L 4-Cylinder (PowerTech), 3.7L V6 ( নাইসলে ) Performance 2.4L Horsepower: Approx. 147-150 hp 2.4L Torque: Approx. 165-170 lb-ft 3.7L V6 Horsepower: Approx. 205-210 hp 3.7L V6 Torque: Approx. 235-240 lb-ft Fuel System Fuel Delivery: Multi-point fuel injection (MPFI) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Standard Transmission: 4-Speed Automatic (42RLE) Optional Optional Transmission: 5-Speed Manual (NV1500 / NV3500 variants, depending on engine and market) Features Drivetrain: Part-time 4WD (Command-Trac), optional Full-time 4WD (Selec-Trac) 📐 Dimensions Exterior Wheelbase: Approx. 104.3 inches (2649 mm) Overall Length: Approx. 174.5 inches (4432 mm) Overall Width: Approx. 71.7 inches (1821 mm) Overall Height: Approx. 68.2 inches (1732 mm) Weights Curb Weight Min: Approx. 3,500 lbs (1588 kg) Towing Capacity: Up to 3,500 lbs (1588 kg) (with appropriate towing package and engine) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (4/5 stars) NHTSA Front Impact Passenger: Good (4/5 stars) IIHS Frontal Offset: Acceptable Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Available (Traction Control System - TCS) Stability Control: Available (Electronic Stability Program - ESP) on later models Passive Features Airbags: Standard front airbags, optional side curtain airbags 💡 Technology Features Infotainment Infotainment System: Base models featured a simple AM/FM/CD player. Higher trims offered premium audio systems, optional CD changers, and satellite radio readiness. Driver Assistance Driver Assistance Features: Limited by modern standards. Primarily ABS, optional Traction Control, and optional ESP. Connectivity Connectivity Options: Auxiliary input jacks for audio devices became more common during this generation. Limited Bluetooth integration on later or higher trim models. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, depending on driving conditions. Refer to manual for specific oil type. Tire Rotation Interval: Every 7,500 miles (12,000 km) Transmission Fluid Change: Check manual for specific interval, typically around 50,000-100,000 miles for automatic transmissions, depending on usage. Fluid Specifications Engine Oil Type: Refer to manual for exact specification; typically SAE 5W-30 (synthetic blend or full synthetic recommended for optimal performance and protection). Coolant Type: Chrysler/Dodge/Jeep HOAT (Hybrid Organic Acid Technology) Orange coolant, or equivalent Mopar antifreeze. Brake Fluid Type: DOT 3 or DOT 4 Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid) Known Issues Common Issues: Actuator failures (HVAC, 4WD), oil leaks (e.g., valve cover gaskets, oil pan), minor electrical gremlins, potential for brake component wear. 📚 Vehicle History Brand Heritage Jeep Legacy: Jeep has a long-standing reputation for robust, go-anywhere capability, originating from its military roots. Model Evolution Kj Generation: The KJ Cherokee (2002-2007) was a significant departure from its XJ predecessor, featuring a unibody construction and a more modern design. Production Manufacturing Location: Toledo, Ohio, USA 🏆 Awards & Recognition Recognitions Award Mentions: The KJ Cherokee generally received positive reviews for its off-road prowess and distinct styling, though some reviewers noted engine power limitations, particularly for the 4-cylinder.
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Jeep Cherokee KJ 2002-2007 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007
Codes
Chassis Code:
KJ
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Sport Utility Vehicle
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester
Key Features
Vehicle Highlights:
Renowned Jeep off-road capability in a more compact and refined package, available with multiple powertrain options.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Language:
English
Format:
PDF
Primary Audience:
Mechanical Technicians
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, engine performance diagnostics
Transmission Systems:
Automatic Transmission (42RLE), manual transmission (NV1500/NV3500 if applicable), clutch, transfer case, driveline
Brake Systems:
Front and rear disc brakes, ABS, parking brake
Steering Suspension:
Power steering, steering gear, suspension components (front and rear), shocks, struts, springs
Electrical Systems:
Battery, charging system, starting system, lighting, instrumentation, body controls, comfort systems, wiring diagrams
Body Chassis:
Body construction, interior trim, exterior trim, doors, glass, HVAC system, frame, exhaust system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting charts
Repair:
Step-by-step repair procedures for all major systems, component removal and installation
Diagnostics:
On-Board Diagnostics (OBD-II) system information, diagnostic trouble codes (DTCs), scan tool usage
Technical Depth
Depth Of Information:
Comprehensive; covers routine maintenance, diagnostics, component repair, and overhaul procedures.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text, printable pages
Binding Type
Binding:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.4L 4-Cylinder (PowerTech), 3.7L V6 ( নাইসলে )
Performance
2.4L Horsepower:
Approx. 147-150 hp
2.4L Torque:
Approx. 165-170 lb-ft
3.7L V6 Horsepower:
Approx. 205-210 hp
3.7L V6 Torque:
Approx. 235-240 lb-ft
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPFI)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Standard Transmission:
4-Speed Automatic (42RLE)
Optional
Optional Transmission:
5-Speed Manual (NV1500 / NV3500 variants, depending on engine and market)
Features
Drivetrain:
Part-time 4WD (Command-Trac), optional Full-time 4WD (Selec-Trac)
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.3 inches (2649 mm)
Overall Length:
Approx. 174.5 inches (4432 mm)
Overall Width:
Approx. 71.7 inches (1821 mm)
Overall Height:
Approx. 68.2 inches (1732 mm)
Weights
Curb Weight Min:
Approx. 3,500 lbs (1588 kg)
Towing Capacity:
Up to 3,500 lbs (1588 kg) (with appropriate towing package and engine)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (4/5 stars)
NHTSA Front Impact Passenger:
Good (4/5 stars)
IIHS Frontal Offset:
Acceptable
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Available (Traction Control System - TCS)
Stability Control:
Available (Electronic Stability Program - ESP) on later models
Passive Features
Airbags:
Standard front airbags, optional side curtain airbags
💡 Technology Features
Infotainment
Infotainment System:
Base models featured a simple AM/FM/CD player. Higher trims offered premium audio systems, optional CD changers, and satellite radio readiness.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily ABS, optional Traction Control, and optional ESP.
Connectivity
Connectivity Options:
Auxiliary input jacks for audio devices became more common during this generation. Limited Bluetooth integration on later or higher trim models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, depending on driving conditions. Refer to manual for specific oil type.
Tire Rotation Interval:
Every 7,500 miles (12,000 km)
Transmission Fluid Change:
Check manual for specific interval, typically around 50,000-100,000 miles for automatic transmissions, depending on usage.
Fluid Specifications
Engine Oil Type:
Refer to manual for exact specification; typically SAE 5W-30 (synthetic blend or full synthetic recommended for optimal performance and protection).
Coolant Type:
Chrysler/Dodge/Jeep HOAT (Hybrid Organic Acid Technology) Orange coolant, or equivalent Mopar antifreeze.
Brake Fluid Type:
DOT 3 or DOT 4
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid)
Known Issues
Common Issues:
Actuator failures (HVAC, 4WD), oil leaks (e.g., valve cover gaskets, oil pan), minor electrical gremlins, potential for brake component wear.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long-standing reputation for robust, go-anywhere capability, originating from its military roots.
Model Evolution
Kj Generation:
The KJ Cherokee (2002-2007) was a significant departure from its XJ predecessor, featuring a unibody construction and a more modern design.
Production
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Award Mentions:
The KJ Cherokee generally received positive reviews for its off-road prowess and distinct styling, though some reviewers noted engine power limitations, particularly for the 4-cylinder.
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