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Jeep LIBERTY KJ Factory Service Repair Manual 2004

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🏷️ Basic Information Identification Make: Jeep Model: Liberty Model Code: KJ Year: 2004 👋 Introduction Market Position Segment: Compact SUV, known for its off-road capability and rugged styling Competitive Analysis Competitors 2004: Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra, Subaru Forester Key Features Styling: Distinctive Jeep styling with a boxy, utilitarian design and prominent grille Powertrain: Available with the robust 3.7L V6 PowerTech engine and capable 4WD systems Capability: Strong off-road performance due to solid rear axle and available 4WD systems 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance for the 2004 Jeep Liberty KJ Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair of all engine components (e.g., cylinder head, block, pistons, crankshaft, camshafts) Engine Management: Diagnosis and repair of the powertrain control module (PCM), fuel injection, ignition system, sensors, actuators, and emissions control Transmission Manual: Service and repair procedures for the NV3500 manual transmission, including clutch, gearbox, and shifting mechanisms Transmission Automatic: Service and repair procedures for the 45RFE/48RE automatic transmission, including valve body, torque converter, and internal components Drivetrain 4Wd: Service and repair of the Command-Trac NV231J or Selec-Trac NV242 transfer case, front and rear axle assemblies (Dana 30/35), CV joints, and driveshafts Suspension Front: Repair and alignment of the independent front suspension system (short-long arm design), including control arms, ball joints, bushings, and springs Suspension Rear: Service and repair of the solid rear axle, leaf springs, shock absorbers, and axle housing Steering: Diagnosis and repair of the power steering system, steering gear, intermediate shaft, and steering column Brakes: Service and repair of front disc and rear drum/disc brakes, including ABS, brake lines, calipers, rotors, pads, and master cylinder Electrical System: Complete wiring diagrams, component locations, troubleshooting guides for all electrical systems (lighting, power windows, mirrors, instruments) Body Exterior: Body panel removal and installation, doors, hood, tailgate, bumpers, glass, and seals Body Interior: Dashboard, seats, upholstery, trim panels, HVAC controls, and sound insulation HVAC: Service and repair of the heating, ventilation, and air conditioning system, including compressor, condenser, evaporator, and refrigerant handling Safety Systems: Airbag system diagnosis and repair, seat belt mechanisms, and child restraint anchorages Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, battery testing, and spark plug replacement Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls, and electrical system diagnostics Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common and complex issues across all vehicle systems Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures Technical Depth Depth: Factory-level diagnostic and repair information, suitable for professional technicians and experienced DIYers 📊 Manual Specifications File Format Searchability: Fully searchable PDF text for quick information retrieval Resolution: High-resolution scans ensuring clear diagrams and text Print Quality Printability: Printable pages for on-site workshop use Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: ECA Engine Description: 3.7L V6 PowerTech (SOHC) Performance Horsepower Hp: 210 hp @ 5200 rpm Torque Lb Ft: 235 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management ECU Type: Chrysler NGC (Next Generation Controller) Cooling System Coolant Type: Chrysler OAT (Organic Acid Technology) or equivalent Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula (MS-9769) Lubrication Oil Type: SAE 5W-30 (API Certified) Oil Capacity Qts: 5.0 (with filter) Emissions Emissions Control: Catalytic Converter, Oxygen Sensors, EGR (on some models) 🔧 Transmission Standard Type Std: 45RFE 4-Speed Automatic Transmission Optional Type Opt: NV3500 5-Speed Manual Transmission Features Automatic Fluid Type: ATF+4 (Mopar) Manual Fluid Type: MS-9224 (Manual Transmission Fluid) Transfer Case Fluid: MS-9424 (Transfer Case Lubricant) 📐 Dimensions Exterior Wheelbase In: 104.2 Length In: 172.4 Width In: 72.4 Height In: 66.4 Weights Curb Weight Lbs Min: 3900 (approx.) Towing Capacity Lbs: Up to 3500 lbs (depending on configuration) Payload Capacity Lbs: Approx. 1000 lbs Wheels Tires Standard Tire Size: P225/75R16 Optional Tire Size: P235/70R16, P235/65R17 Bolt Pattern: 5x114.3 (5x4.5 inches) Wheel Size Std: 16x7 inches 🛡️ Safety Features Ratings NHTSA Front Driver Impact: Good NHTSA Front Passenger Impact: Good NHTSA Side Driver Impact: Acceptable NHTSA Side Rear Passenger Impact: Acceptable Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Passive Features Airbags Front: Standard driver and passenger front airbags Seat Belts: Three-point seat belts with pretensioners Rollover Detection: Feature available on some models (ESP) 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional Infinity premium audio system Navigation: Optional aftermarket or dealer-installed navigation units Driver Assistance Cruise Control: Standard Connectivity Auxiliary Input: N/A (typical for this era) 🔧 Maintenance Service Intervals Oil Change Interval Miles: Every 3,000 - 7,500 miles or 6 months,...
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Jeep LIBERTY KJ Factory Service Repair Manual 2004
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Liberty
Model Code:
KJ
Year:
2004
👋 Introduction
Market Position
Segment:
Compact SUV, known for its off-road capability and rugged styling
Competitive Analysis
Competitors 2004:
Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra, Subaru Forester
Key Features
Styling:
Distinctive Jeep styling with a boxy, utilitarian design and prominent grille
Powertrain:
Available with the robust 3.7L V6 PowerTech engine and capable 4WD systems
Capability:
Strong off-road performance due to solid rear axle and available 4WD systems
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, and maintenance for the 2004 Jeep Liberty KJ
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of all engine components (e.g., cylinder head, block, pistons, crankshaft, camshafts)
Engine Management:
Diagnosis and repair of the powertrain control module (PCM), fuel injection, ignition system, sensors, actuators, and emissions control
Transmission Manual:
Service and repair procedures for the NV3500 manual transmission, including clutch, gearbox, and shifting mechanisms
Transmission Automatic:
Service and repair procedures for the 45RFE/48RE automatic transmission, including valve body, torque converter, and internal components
Drivetrain 4Wd:
Service and repair of the Command-Trac NV231J or Selec-Trac NV242 transfer case, front and rear axle assemblies (Dana 30/35), CV joints, and driveshafts
Suspension Front:
Repair and alignment of the independent front suspension system (short-long arm design), including control arms, ball joints, bushings, and springs
Suspension Rear:
Service and repair of the solid rear axle, leaf springs, shock absorbers, and axle housing
Steering:
Diagnosis and repair of the power steering system, steering gear, intermediate shaft, and steering column
Brakes:
Service and repair of front disc and rear drum/disc brakes, including ABS, brake lines, calipers, rotors, pads, and master cylinder
Electrical System:
Complete wiring diagrams, component locations, troubleshooting guides for all electrical systems (lighting, power windows, mirrors, instruments)
Body Exterior:
Body panel removal and installation, doors, hood, tailgate, bumpers, glass, and seals
Body Interior:
Dashboard, seats, upholstery, trim panels, HVAC controls, and sound insulation
HVAC:
Service and repair of the heating, ventilation, and air conditioning system, including compressor, condenser, evaporator, and refrigerant handling
Safety Systems:
Airbag system diagnosis and repair, seat belt mechanisms, and child restraint anchorages
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, battery testing, and spark plug replacement
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls, and electrical system diagnostics
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and complex issues across all vehicle systems
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures
Technical Depth
Depth:
Factory-level diagnostic and repair information, suitable for professional technicians and experienced DIYers
📊 Manual Specifications
File Format
Searchability:
Fully searchable PDF text for quick information retrieval
Resolution:
High-resolution scans ensuring clear diagrams and text
Print Quality
Printability:
Printable pages for on-site workshop use
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
ECA
Engine Description:
3.7L V6 PowerTech (SOHC)
Performance
Horsepower Hp:
210 hp @ 5200 rpm
Torque Lb Ft:
235 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Chrysler NGC (Next Generation Controller)
Cooling System
Coolant Type:
Chrysler OAT (Organic Acid Technology) or equivalent Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula (MS-9769)
Lubrication
Oil Type:
SAE 5W-30 (API Certified)
Oil Capacity Qts:
5.0 (with filter)
Emissions
Emissions Control:
Catalytic Converter, Oxygen Sensors, EGR (on some models)
🔧 Transmission
Standard
Type Std:
45RFE 4-Speed Automatic Transmission
Optional
Type Opt:
NV3500 5-Speed Manual Transmission
Features
Automatic Fluid Type:
ATF+4 (Mopar)
Manual Fluid Type:
MS-9224 (Manual Transmission Fluid)
Transfer Case Fluid:
MS-9424 (Transfer Case Lubricant)
📐 Dimensions
Exterior
Wheelbase In:
104.2
Length In:
172.4
Width In:
72.4
Height In:
66.4
Weights
Curb Weight Lbs Min:
3900 (approx.)
Towing Capacity Lbs:
Up to 3500 lbs (depending on configuration)
Payload Capacity Lbs:
Approx. 1000 lbs
Wheels Tires
Standard Tire Size:
P225/75R16
Optional Tire Size:
P235/70R16, P235/65R17
Bolt Pattern:
5x114.3 (5x4.5 inches)
Wheel Size Std:
16x7 inches
🛡️ Safety Features
Ratings
NHTSA Front Driver Impact:
Good
NHTSA Front Passenger Impact:
Good
NHTSA Side Driver Impact:
Acceptable
NHTSA Side Rear Passenger Impact:
Acceptable
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional
Passive Features
Airbags Front:
Standard driver and passenger front airbags
Seat Belts:
Three-point seat belts with pretensioners
Rollover Detection:
Feature available on some models (ESP)
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional Infinity premium audio system
Navigation:
Optional aftermarket or dealer-installed navigation units
Driver Assistance
Cruise Control:
Standard
Connectivity
Auxiliary Input:
N/A (typical for this era)
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
Every 3,000 - 7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics)
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection
Spark Plug Replacement:
Approximately 100,000 miles (Long Life Platinum)
Transmission Fluid Change Auto:
Every 30,000 - 60,000 miles or as per severe service schedule
Transmission Fluid Change Manual:
Every 60,000 - 100,000 miles
Coolant Replacement:
Every 5 years or 100,000 miles
Fluid Specifications
Power Steering Fluid:
ATF+4 (Mopar)
Brake Fluid:
DOT 3
Known Issues
Common Problems:
Rear main seal leaks, differential pinion seal leaks, radiator leaks, death wobble (front suspension issues), HVAC blower motor resistor failure, PCM failure
📚 Vehicle History
Brand Heritage
Brand Identity:
Jeep, a brand renowned for its off-road prowess and adventurous spirit since its WWII origins
Model Evolution
Generation:
First Generation (KJ)
Introduction Year:
2001 (for the 2002 model year)
Platform:
Shared platform with Mitsubishi Pajero Sport (first gen), later diversified
Production
Production Years Kj:
2002-2007
Assembly Locations:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
None significantly noted as a class leader, often praised for capability over refined road manners.
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