Jeep Cherokee KJ 2002-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: KJ Generation: Second Generation (KJ) Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover SUV Jeep Heritage: Continuation of Jeep's legacy in off-road capable vehicles, adapted for a more urban and family-oriented market. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (early models), Subaru Forester Key Features Distinctive Attributes: Jeep's characteristic styling, available Freedom Drive II 4WD system for enhanced off-road capability, comfortable ride, practical interior. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Service and Repair Geographic Coverage: Global (with potential regional variations noted) Page Count Estimated Pages: Over 2000 pages (typical for comprehensive factory service manuals) Manual Type Manual Category: Factory Service Manual (FSM) / Workshop Manual Language Primary Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing system Engine Performance: Fuel system, ignition system, emissions control system, engine diagnostics, turbocharger system (if applicable) Transmission Manual: Clutch, manual transmission assembly, gear shift mechanism, driveline Transmission Automatic: Automatic transmission assembly, torque converter, transmission control module (TCM), hydraulic system, valve body Drivetrain: Transfer case, front axle, rear axle, differentials, driveshafts, U-joints, CV joints Suspension: Front suspension (independent), rear suspension (solid axle), shock absorbers, springs, control arms, stabilizer bars Steering: Steering gear, power steering system, steering column, tie rods, steering linkage Brakes: Front and rear brake systems (disc/drum), ABS, EBD, brake lines, master cylinder, calipers, rotors, pads Electrical System: Battery, charging system (alternator, regulator), starting system (starter), lighting system (headlights, taillights, interior), horn, wipers, washers Body Electrical: Body control module (BCM), power windows, power locks, mirrors, seats, remote keyless entry, interior trim, exterior trim, mirrors HVAC: Heating, ventilation, air conditioning system, refrigerant, compressor, condenser, evaporator, blower motor, control panel Chassis Controls: Traction control system (TCS), electronic stability program (ESP/ESC) Restraints: Airbag system, seat belt system, SRS module Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, brake pad inspection Diagnostic Troubleshooting: Step-by-step diagnostic charts, symptom-based troubleshooting, wiring diagrams, connector pinouts, diagnostic trouble codes (DTCs) Component Repair Replacement: Detailed instructions for removing, inspecting, repairing, and reinstalling all major and minor components Rebuilds Overhauls: Engine, transmission, and axle overhaul procedures with specifications Electrical Diagnostics: Wiring schematics, troubleshooting for electrical faults, sensor testing, module programming Body And Frame: Body panel removal/installation, collision repair guidelines, structural repair Emissions Systems: Diagnosis and repair of evaporative emissions control (EVAP), catalytic converter, oxygen sensors, EGR HVAC Service: Refrigerant handling, system charging, component replacement, leak detection Wheel Alignment And Balancing: Alignment specifications and procedures, wheel balancing instructions Technical Depth Depth Level: Expert/Professional Level Diagnostic Tools: References to diagnostic scan tools, specialized equipment, and measurement tools Specifications And Tolerances: Precise measurements, torque values, clearances, and operating parameters for all components Wiring Diagrams: Detailed, system-specific wiring schematics with component locations and connector views Troubleshooting Charts: Flowchart-based troubleshooting guides for common and complex issues 📊 Manual Specifications File Format Document Type: PDF Searchability: Likely searchable text (depending on original scan quality) Printability: Printable (user discretion advised for large documents) Print Quality Image Resolution: Variable (dependent on original source, but typically clear line drawings and photos) Binding Type Binding Method: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Gas: 2.4L PowerTech (ED1) Engine Displacement Gas: 2429 cc (148.2 cubic inches) Engine Configuration Gas: Inline 4-cylinder, DOHC, 16-valve Horsepower Gas: 150 hp @ 5800 rpm Torque Gas: 165 lb-ft @ 4000 rpm Optional Engine Engine Code Gas Optional: 2.7L PowerTech V6 (2.7L HO V6) Engine Displacement Gas Optional: 2700 cc (164.8 cubic inches) Engine Configuration Gas Optional: V6, SOHC, 24-valve Horsepower Gas Optional: 190 hp @ 6000 rpm Torque Gas Optional: 205 lb-ft @ 4500 rpm Engine Code Gas Optional 2: 3.7L PowerTech V6 Engine Displacement Gas Optional 2: 3700 cc (226 cubic inches) Engine Configuration Gas Optional 2: V6, SOHC, 24-valve Horsepower Gas Optional 2: 201 hp @ 5200 rpm Torque Gas Optional 2: 230 lb-ft @ 3800 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 Octane (minimum) 🔧 Transmission Standard Transmission Type Gas: 5-Speed Manual (NV1500) Optional Transmission Type Auto: 4-Speed Automatic (42RLE) Features Drivetrain Options: 2WD (Rear-Wheel Drive), 4WD (Command-Trac NV237, Freedom Drive I, Freedom Drive II with low range and locking center differential) Transfer Case: NV235/NV237 (part-time 2-speed transfer case) Fluid Specs Automatic Transmission Fluid: Chrysler ATF+4 (MS-9602) Manual Transmission Fluid: Mopar Manual Transmission Lubricant or equivalent API GL-3/GL-4, SAE 75W-90 📐 Dimensions Exterior Length: Approx. 173.5 inches (4407 mm) Width: Approx. 71.5 inches (1816 mm) Height: Approx. 66.9 inches (1700 mm) Wheelbase: Approx. 104.2 inches (2647 mm) Interior Passenger Volume: Approx. 94.5...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Model Code:

Generation:

Second Generation (KJ)

Years Covered:

2002, 2003, 2004, 2005, 2006, 2007

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Crossover SUV

Jeep Heritage:

Continuation of Jeep's legacy in off-road capable vehicles, adapted for a more urban and family-oriented market.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (early models), Subaru Forester

Key Features

Distinctive Attributes:

Jeep's characteristic styling, available Freedom Drive II 4WD system for enhanced off-road capability, comfortable ride, practical interior.

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Service and Repair

Geographic Coverage:

Global (with potential regional variations noted)

Page Count

Estimated Pages:

Over 2000 pages (typical for comprehensive factory service manuals)

Manual Type

Manual Category:

Factory Service Manual (FSM) / Workshop Manual

Language

Primary Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing system

Engine Performance:

Fuel system, ignition system, emissions control system, engine diagnostics, turbocharger system (if applicable)

Transmission Manual:

Clutch, manual transmission assembly, gear shift mechanism, driveline

Transmission Automatic:

Automatic transmission assembly, torque converter, transmission control module (TCM), hydraulic system, valve body

Drivetrain:

Transfer case, front axle, rear axle, differentials, driveshafts, U-joints, CV joints

Suspension:

Front suspension (independent), rear suspension (solid axle), shock absorbers, springs, control arms, stabilizer bars

Steering:

Steering gear, power steering system, steering column, tie rods, steering linkage

Brakes:

Front and rear brake systems (disc/drum), ABS, EBD, brake lines, master cylinder, calipers, rotors, pads

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter), lighting system (headlights, taillights, interior), horn, wipers, washers

Body Electrical:

Body control module (BCM), power windows, power locks, mirrors, seats, remote keyless entry, interior trim, exterior trim, mirrors

HVAC:

Heating, ventilation, air conditioning system, refrigerant, compressor, condenser, evaporator, blower motor, control panel

Chassis Controls:

Traction control system (TCS), electronic stability program (ESP/ESC)

Restraints:

Airbag system, seat belt system, SRS module

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, brake pad inspection

Diagnostic Troubleshooting:

Step-by-step diagnostic charts, symptom-based troubleshooting, wiring diagrams, connector pinouts, diagnostic trouble codes (DTCs)

Component Repair Replacement:

Detailed instructions for removing, inspecting, repairing, and reinstalling all major and minor components

Rebuilds Overhauls:

Engine, transmission, and axle overhaul procedures with specifications

Electrical Diagnostics:

Wiring schematics, troubleshooting for electrical faults, sensor testing, module programming

Body And Frame:

Body panel removal/installation, collision repair guidelines, structural repair

Emissions Systems:

Diagnosis and repair of evaporative emissions control (EVAP), catalytic converter, oxygen sensors, EGR

HVAC Service:

Refrigerant handling, system charging, component replacement, leak detection

Wheel Alignment And Balancing:

Alignment specifications and procedures, wheel balancing instructions

Technical Depth

Depth Level:

Expert/Professional Level

Diagnostic Tools:

References to diagnostic scan tools, specialized equipment, and measurement tools

Specifications And Tolerances:

Precise measurements, torque values, clearances, and operating parameters for all components

Wiring Diagrams:

Detailed, system-specific wiring schematics with component locations and connector views

Troubleshooting Charts:

Flowchart-based troubleshooting guides for common and complex issues

📊 Manual Specifications

File Format

Document Type:

Searchability:

Likely searchable text (depending on original scan quality)

Printability:

Printable (user discretion advised for large documents)

Print Quality

Image Resolution:

Variable (dependent on original source, but typically clear line drawings and photos)

Binding Type

Binding Method:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code Gas:

2.4L PowerTech (ED1)

Engine Displacement Gas:

2429 cc (148.2 cubic inches)

Engine Configuration Gas:

Inline 4-cylinder, DOHC, 16-valve

Horsepower Gas:

150 hp @ 5800 rpm

Torque Gas:

165 lb-ft @ 4000 rpm

Optional Engine

Engine Code Gas Optional:

2.7L PowerTech V6 (2.7L HO V6)

Engine Displacement Gas Optional:

2700 cc (164.8 cubic inches)

Engine Configuration Gas Optional:

V6, SOHC, 24-valve

Horsepower Gas Optional:

190 hp @ 6000 rpm

Torque Gas Optional:

205 lb-ft @ 4500 rpm

Engine Code Gas Optional 2:

3.7L PowerTech V6

Engine Displacement Gas Optional 2:

3700 cc (226 cubic inches)

Engine Configuration Gas Optional 2:

V6, SOHC, 24-valve

Horsepower Gas Optional 2:

201 hp @ 5200 rpm

Torque Gas Optional 2:

230 lb-ft @ 3800 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Recommended Octane:

87 Octane (minimum)

🔧 Transmission

Standard

Transmission Type Gas:

5-Speed Manual (NV1500)

Optional

Transmission Type Auto:

4-Speed Automatic (42RLE)

Features

Drivetrain Options:

2WD (Rear-Wheel Drive), 4WD (Command-Trac NV237, Freedom Drive I, Freedom Drive II with low range and locking center differential)

Transfer Case:

NV235/NV237 (part-time 2-speed transfer case)

Fluid Specs

Automatic Transmission Fluid:

Chrysler ATF+4 (MS-9602)

Manual Transmission Fluid:

Mopar Manual Transmission Lubricant or equivalent API GL-3/GL-4, SAE 75W-90

📐 Dimensions

Exterior

Length:

Approx. 173.5 inches (4407 mm)

Width:

Approx. 71.5 inches (1816 mm)

Height:

Approx. 66.9 inches (1700 mm)

Wheelbase:

Approx. 104.2 inches (2647 mm)

Interior

Passenger Volume:

Approx. 94.5 cubic feet (2676 liters)

Cargo

Cargo Volume Behind Rear Seat:

Approx. 31.5 cubic feet (892 liters)

Cargo Volume With Rear Seat Folded:

Approx. 69.1 cubic feet (1956 liters)

Weights

Curb Weight:

Approx. 3500 - 3900 lbs (1588 - 1769 kg) depending on configuration

Gross Vehicle Weight Rating Gvwr:

Approx. 4600 - 4950 lbs (2087 - 2245 kg)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Driver:

Good (2003 model year tested)

NHTSA Front Crash Test Passenger:

Good (2003 model year tested)

NHTSA Side Impact Front Seat:

Good (2003 model year tested)

NHTSA Side Impact Rear Seat:

Good (2003 model year tested)

IIHS Front Offset Crash Test:

Good (varies by year, generally good for the generation)

Active Features

Traction Control:

Standard on most models

Electronic Stability Control:

Optional on some models, standard on later models

Anti Lock Brakes:

Standard

Passive Features

Airbags:

Front airbags, optional side curtain airbags

Seat Belts:

3-point front and rear seat belts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Infinity premium audio system, available SiriusXM satellite radio.

Navigation:

Optional factory navigation system available on higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Remote Keyless Entry:

Available on most models.

Power Accessories:

Power windows, power door locks, power mirrors standard on many trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first (refer to manual for specific engine/oil type).

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km), inspect more frequently.

Spark Plug Replacement:

Every 30,000 - 100,000 miles (48,000 - 160,000 km) depending on spark plug type (platinum/iridium recommended).

Coolant Flush Interval:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-5 years.

Transmission Fluid Change Auto:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), especially under severe use.

Brake Fluid Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (preferred) or 5W-20 (check owner's manual and ambient temperature chart)

Engine Oil Capacity:

2.4L: 4.5 US quarts (4.3 L); 2.7L V6: 5.0 US quarts (4.7 L); 3.7L V6: 6.0 US quarts (5.7 L)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent meeting MS-9769

Power Steering Fluid:

Chrysler Power Steering Fluid or equivalent meeting MS-5901

Known Issues

Common Problem 1:

Heater core leaks (especially with the 2.7L V6)

Common Problem 2:

Blend door actuator failures (HVAC system)

Common Problem 3:

Oil filter housing leaks (common on Jeep engines of this era)

Common Problem 4:

Sway bar link and bushing wear (typical for SUVs)

Common Problem 5:

Minor electrical gremlins, particularly related to door modules or sensors.

Common Problem 6:

Transmission cooler line leaks (potential for fluid loss)

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Founded in 1941, Jeep is synonymous with off-road capability and adventure. The brand has a storied history with military vehicles and has evolved to offer a diverse range of SUVs.

Model Evolution

Kj Generation Introduction:

The KJ Cherokee (Liberty in North America) was introduced for the 2002 model year, replacing the XJ Cherokee. It featured a more modern unibody construction with a more rugged, upright styling compared to its predecessor.

Kj Generation Updates:

Key updates during its lifecycle included revised powertrains (introduction of the 3.7L V6 replacing the 2.7L V6 for many markets), interior refinements, and updated feature availability. The exterior styling remained largely consistent.

Production

Production Locations:

Toledo, Ohio, USA; also assembled in other locations globally.

Production Years Kj:

2002-2007

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

While not always a specific 'award', consistently good crash test ratings from IIHS and NHTSA were a strong selling point.

Off Road Capability Recognition:

Praised for its off-road capability, especially with the Freedom Drive II system, maintaining Jeep's reputation.