The Best 2002 Jeep Grand Cherokee Factory Service Manual

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🏷️ Basic Information Identification Make: Jeep Model: Grand Cherokee Year: 2002 Platform: WJ Trims Covered: Sport, Laredo, Limited, Overland Engine Variants Covered: 4.0L I6, 4.7L V8 Codes Vin Character Engine: 6 (4.0L), X (4.7L) 👋 Introduction Market Position Target Audience: DIY Enthusiasts, Independent Repair Shops, Jeep Grand Cherokee Owners seeking to understand and maintain their vehicle Competitive Analysis Advantage: Authentic factory data provides superior accuracy and completeness compared to aftermarket repair manuals Cost Saving Potential: Enables DIY repairs, significantly reducing labor costs at dealerships or independent shops Key Features Content Scope: Extremely broad coverage, encompassing nearly all vehicle systems and maintenance/repair procedures Usability: Print-on-demand capability allows users to access only necessary information and use it in a workshop environment Data Integrity: Official factory documentation ensures accuracy of specifications, procedures, and diagnostic information 📋 Manual Details Coverage Areas Primary Focus: Service, Diagnosis, Repair Geographic Coverage: North America (implied by engine options and market) Page Count Estimated Pages: Extensive (typically 2000+ pages for a complete factory service manual) Manual Type Type: Factory Service Manual (FSM) Source Equivalent: Mechanic and Dealership Level Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Control Systems, Fuel System, Cooling System, Exhaust System, Turbocharger (if applicable), Transmission (Automatic), Transfer Case, Driveline (Front/Rear Axles, Differentials) Chassis: Suspension (Front/Rear), Steering System, Brakes (Hydraulic, ABS, Parking Brake), Wheels and Tires Electrical: Battery, Starting System, Charging System, Ignition System, Instrument Panel Systems, Audio Systems, Horn Systems, Vehicle Speed Control System, Turn Signal and Hazard Warning Systems, Wipers and Washer Systems, Lamps, Passive Restraint Systems, Electrically Heated Systems, Power Distribution Systems, Power Lock Systems, Vehicle Theft/Security Systems, Power Seat Systems, Power Window Systems, Power Mirror Systems, Chime/Buzzer Warning Systems, Overhead Console Systems, Wiring Diagrams Body: Frame and Bumpers, Body Panels, Interior Trim, Doors, Windows, Mirrors, Seats, Roof Systems HVAC: Heating and Air Conditioning (A/C) System Emissions: Emission Control System Procedures Included Maintenance: Lubrication, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid, Differential Fluid), Filter Replacements, Belt Inspection/Replacement, Spark Plug Replacement, Tune-Up Procedures Diagnosis: Troubleshooting Charts, Symptom-Based Diagnostics, OBD-II Code Interpretation, Component Testing Procedures, Diagnostic Tool Usage Repair: Component Removal and Installation, Overhaul Procedures, Component Rebuilding, Body Repair, Electrical Component Replacement Specifications: Torque Specifications, Clearances, Fluid Capacities, Electrical Values, Component Dimensions Technical Depth Depth: Comprehensive from basic maintenance to in-depth engine and transmission rebuilds Diagnostic Capabilities: Advanced diagnostic procedures for all major systems, including electrical schematics and pinpoint tests Visual Aids Illustrations: Photos, Exploded Views, Diagrams, Wiring Schematics 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within PDF (standard for modern FSMs) Print Quality Printability: High-quality, suitable for printing individual pages or sections Digital Viewing: Optimized for digital viewing on PC or Mac Binding Type Digital Binding: N/A (Downloadable File) Paper Type Digital Paper: N/A (Digital Format) Software Requirements Reader: Adobe Acrobat Reader X (or later) Access: Internet Connection for Download ⚙️ Engine Specifications Primary Engine 4.0L I6: 4.0L (3952cc) Inline 6-cylinder, OHV, 12-valve. Known for robust design and longevity. Power output typically around 190-200 hp and 225-235 lb-ft of torque. 4.7L V8: 4.7L (4701cc) V8, SOHC, 16-valve (PowerTech engine). Offers more power and torque, typically around 235-260 hp and 295-325 lb-ft of torque depending on specific version. Performance 4.0L Fuel System: Sequential Multi-Port Fuel Injection (MPI) 4.7L Fuel System: Sequential Multi-Port Fuel Injection (MPI) Ignition System: Distributorless Ignition System (DIS) with coil-on-plug (COP) or waste spark depending on sub-model/year specifics for the 4.7L, and distributor with coil for the 4.0L. Cooling System: Pressurized liquid cooling system with engine-driven fan or electric cooling fan (depending on configuration). Maintenance 4.0L Oil Capacity: 5.0 US Quarts (4.7 Liters) with filter (check specific model for exact capacity) 4.7L Oil Capacity: 6.0 US Quarts (5.7 Liters) with filter (check specific model for exact capacity) Recommended Engine Oil: API Certified SAE 5W-30 (check specific manual for exact specification, especially for different temperature ranges and synthetic options) 4.0L Spark Plugs: Typically Champion Copper Plus (e.g., RC12LYC) or equivalent. Service interval varies, often around 30,000 miles, but platinum/iridium plugs offer longer life. 4.7L Spark Plugs: Typically NGK Platinum (e.g., PFR5N-11) or similar. Service interval typically 60,000-100,000 miles depending on plug type. Known Issues 4.0L Common: Head gasket leaks (especially earlier WJ models), oil filter adapter O-ring leaks, intake manifold gasket leaks, valve cover gasket leaks. Known for robust block and bottom end. 4.7L Common: Valve seat recession (especially earlier versions), intake manifold gasket leaks, cracked cylinder heads (less common than early WJ 4.0L head gasket issues but still a concern), oil filter adapter O-ring leaks. 🔧 Transmission Standard Transmission: 42RE (4-speed Automatic) for 4.0L engine; 45RFE/545RFE (4-speed or 5-speed Automatic, depending on model year and specific variant) for 4.7L engine. Transfer Case: Selec-Trac (NV242) or Quadra-Trac II (NV247) depending on trim level and options. Features...

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Tags: 2002 480 Models Backhoe Loaders Car Case Construction Grand Cherokee Jeep

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Grand Cherokee

Year:

Platform:

Trims Covered:

Sport, Laredo, Limited, Overland

Engine Variants Covered:

4.0L I6, 4.7L V8

Codes

Vin Character Engine:

6 (4.0L), X (4.7L)

👋 Introduction

Market Position

Target Audience:

DIY Enthusiasts, Independent Repair Shops, Jeep Grand Cherokee Owners seeking to understand and maintain their vehicle

Competitive Analysis

Advantage:

Authentic factory data provides superior accuracy and completeness compared to aftermarket repair manuals

Cost Saving Potential:

Enables DIY repairs, significantly reducing labor costs at dealerships or independent shops

Key Features

Content Scope:

Extremely broad coverage, encompassing nearly all vehicle systems and maintenance/repair procedures

Usability:

Print-on-demand capability allows users to access only necessary information and use it in a workshop environment

Data Integrity:

Official factory documentation ensures accuracy of specifications, procedures, and diagnostic information

📋 Manual Details

Coverage Areas

Primary Focus:

Service, Diagnosis, Repair

Geographic Coverage:

North America (implied by engine options and market)

Page Count

Estimated Pages:

Extensive (typically 2000+ pages for a complete factory service manual)

Manual Type

Type:

Factory Service Manual (FSM)

Source Equivalent:

Mechanic and Dealership Level

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Engine Control Systems, Fuel System, Cooling System, Exhaust System, Turbocharger (if applicable), Transmission (Automatic), Transfer Case, Driveline (Front/Rear Axles, Differentials)

Chassis:

Suspension (Front/Rear), Steering System, Brakes (Hydraulic, ABS, Parking Brake), Wheels and Tires

Electrical:

Battery, Starting System, Charging System, Ignition System, Instrument Panel Systems, Audio Systems, Horn Systems, Vehicle Speed Control System, Turn Signal and Hazard Warning Systems, Wipers and Washer Systems, Lamps, Passive Restraint Systems, Electrically Heated Systems, Power Distribution Systems, Power Lock Systems, Vehicle Theft/Security Systems, Power Seat Systems, Power Window Systems, Power Mirror Systems, Chime/Buzzer Warning Systems, Overhead Console Systems, Wiring Diagrams

Body:

Frame and Bumpers, Body Panels, Interior Trim, Doors, Windows, Mirrors, Seats, Roof Systems

HVAC:

Heating and Air Conditioning (A/C) System

Emissions:

Emission Control System

Procedures Included

Maintenance:

Lubrication, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid, Power Steering Fluid, Differential Fluid), Filter Replacements, Belt Inspection/Replacement, Spark Plug Replacement, Tune-Up Procedures

Diagnosis:

Troubleshooting Charts, Symptom-Based Diagnostics, OBD-II Code Interpretation, Component Testing Procedures, Diagnostic Tool Usage

Repair:

Component Removal and Installation, Overhaul Procedures, Component Rebuilding, Body Repair, Electrical Component Replacement

Specifications:

Torque Specifications, Clearances, Fluid Capacities, Electrical Values, Component Dimensions

Technical Depth

Depth:

Comprehensive from basic maintenance to in-depth engine and transmission rebuilds

Diagnostic Capabilities:

Advanced diagnostic procedures for all major systems, including electrical schematics and pinpoint tests

Visual Aids

Illustrations:

Photos, Exploded Views, Diagrams, Wiring Schematics

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within PDF (standard for modern FSMs)

Print Quality

Printability:

High-quality, suitable for printing individual pages or sections

Digital Viewing:

Optimized for digital viewing on PC or Mac

Binding Type

Digital Binding:

N/A (Downloadable File)

Paper Type

Digital Paper:

N/A (Digital Format)

Software Requirements

Reader:

Adobe Acrobat Reader X (or later)

Access:

Internet Connection for Download

⚙️ Engine Specifications

Primary Engine

4.0L I6:

4.0L (3952cc) Inline 6-cylinder, OHV, 12-valve. Known for robust design and longevity. Power output typically around 190-200 hp and 225-235 lb-ft of torque.

4.7L V8:

4.7L (4701cc) V8, SOHC, 16-valve (PowerTech engine). Offers more power and torque, typically around 235-260 hp and 295-325 lb-ft of torque depending on specific version.

Performance

4.0L Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

4.7L Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug (COP) or waste spark depending on sub-model/year specifics for the 4.7L, and distributor with coil for the 4.0L.

Cooling System:

Pressurized liquid cooling system with engine-driven fan or electric cooling fan (depending on configuration).

Maintenance

4.0L Oil Capacity:

5.0 US Quarts (4.7 Liters) with filter (check specific model for exact capacity)

4.7L Oil Capacity:

6.0 US Quarts (5.7 Liters) with filter (check specific model for exact capacity)

Recommended Engine Oil:

API Certified SAE 5W-30 (check specific manual for exact specification, especially for different temperature ranges and synthetic options)

4.0L Spark Plugs:

Typically Champion Copper Plus (e.g., RC12LYC) or equivalent. Service interval varies, often around 30,000 miles, but platinum/iridium plugs offer longer life.

4.7L Spark Plugs:

Typically NGK Platinum (e.g., PFR5N-11) or similar. Service interval typically 60,000-100,000 miles depending on plug type.

Known Issues

4.0L Common:

Head gasket leaks (especially earlier WJ models), oil filter adapter O-ring leaks, intake manifold gasket leaks, valve cover gasket leaks. Known for robust block and bottom end.

4.7L Common:

Valve seat recession (especially earlier versions), intake manifold gasket leaks, cracked cylinder heads (less common than early WJ 4.0L head gasket issues but still a concern), oil filter adapter O-ring leaks.

🔧 Transmission

Standard

Transmission:

42RE (4-speed Automatic) for 4.0L engine; 45RFE/545RFE (4-speed or 5-speed Automatic, depending on model year and specific variant) for 4.7L engine.

Transfer Case:

Selec-Trac (NV242) or Quadra-Trac II (NV247) depending on trim level and options.

Features

42Re:

RWD bias, electronically controlled overdrive, torque converter lock-up.

45Rfe/545Rfe:

More advanced, electronically controlled, closer gear ratios, and improved fuel efficiency. The 545RFE adds a 3rd overdrive gear.

Maintenance

Transmission Fluid Type (42Re):

ATF+4 (MS-9602)

Transmission Fluid Type (45Rfe/545Rfe):

ATF+4 (MS-9602)

Transmission Fluid Capacity:

Varies by model, typically around 10-13 US Quarts (9.5-12.3 Liters) for a drain and fill (check specific manual for exact capacity and fill procedure).

Known Issues

Common:

Solenoid issues, torque converter shudder, internal seal leaks, premature wear in older 42RE units. 45RFE/545RFE generally more reliable but can develop electronic control unit (ECU) or solenoid pack issues.

📐 Dimensions

Exterior

Wheelbase:

116.1 inches (2950 mm)

Overall Length:

184.4 inches (4684 mm)

Overall Width:

74.0 inches (1880 mm)

Overall Height:

66.7 inches (1694 mm)

Weights

Curb Weight:

Approximately 4,400 - 4,800 lbs (2000 - 2180 kg) depending on engine and trim.

Towing Capacity:

Up to 6,500 lbs (2948 kg) with appropriate towing package and engine.

Cargo

Cargo Volume (Behind 2Nd Row):

Approx. 37.7 cu. ft.

Cargo Volume (With 2Nd Row Folded):

Approx. 77.0 cu. ft.

Wheel Specifications

Bolt Pattern:

5 x 4.5 inches (5x114.3 mm)

Wheel Size:

Typically 16-inch or 17-inch alloy wheels depending on trim.

Tire Size:

Commonly P235/65R17 or P225/75R16 (check specific trim for exact sizes).

🛡️ Safety Features

Ratings

NHTSA Frontal Crash:

Likely 4-star driver and 4-star passenger (typical for this era of SUV, but precise ratings should be verified for exact model year).

NHTSA Side Impact:

Likely 4-star front and 4-star rear passenger (typical for this era).

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

Available Traction Control System (TCS) on some models.

Stability Control:

Electronic Stability Program (ESP) became available on later WJ models and is a significant safety feature.

Passive Features

Airbags:

Frontal airbags for driver and front passenger. Side curtain airbags or side-impact airbags were optional or standard on higher trims.

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point seatbelts for rear outboard occupants.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

💡 Technology Features

Infotainment

Audio Systems:

Standard AM/FM stereo with CD player. Optional premium audio systems (e.g., Infinity Gold) were available. Some models may have had cassette players or CD changers.

Navigation:

Optional factory navigation system was available on higher trim levels.

Driver Assistance

Cruise Control:

Standard feature.

Parking Sensors:

Rear parking sensors were an optional feature.

Connectivity

Onstar:

Some later WJ models offered OnStar integration.

Wiring Diagrams

Coverage:

Extensive, detailed wiring diagrams for all electrical systems are a hallmark of factory service manuals, crucial for diagnosing complex electrical issues.

🔧 Maintenance

Service Intervals

Engine Oil & Filter Change:

Every 5,000-7,500 miles or 6 months, whichever comes first (using conventional oil); can be extended with synthetic oil (consult manual).

Transmission Fluid & Filter Change:

Typically every 30,000-60,000 miles, depending on driving conditions (severe duty service may require more frequent changes).

Coolant Flush & Replacement:

Every 30,000-50,000 miles or 2-3 years. Use HOAT coolant (Hybrid Organic Acid Technology).

Brake Fluid Flush:

Every 2-3 years or 30,000 miles.

Differential Fluid Change:

Every 30,000-50,000 miles, especially if used for towing or off-roading.

Fluid Specifications

Engine Coolant:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT or equivalent. DO NOT mix with traditional green IAT coolant.

Brake Fluid:

DOT 3 (check manual for specific requirement, some may call for DOT 4).

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent ATF+4 (check specific manual).

Known Issues

4.0L Head Gasket:

A common failure point on earlier WJ 4.0L engines, often leading to coolant loss and overheating. Improved gaskets are available.

Water Pump Leaks:

Can occur on both engines, often indicated by coolant puddles under the front of the engine.

Blend Door Actuators (HVAC):

Failure of the HVAC blend door actuators can lead to improper temperature control or air distribution.

Cracked Exhaust Manifolds (4.7L):

The cast iron exhaust manifolds on the 4.7L can develop cracks due to heat cycling, leading to exhaust leaks and ticking noises.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long-standing reputation for off-road capability and ruggedness, established with the original Willys Jeep.

Model Evolution

Grand Cherokee Wj:

The WJ generation (1999-2004) represented a significant refinement over its predecessor (ZJ). It featured a more integrated unibody structure, improved interior comfort and materials, and more sophisticated powertrain options, particularly the 4.7L V8 'PowerTech' engine.

2002 Model Year Changes:

While 2002 wasn't a major redesign year, it saw refinements in features and options. Electronic Stability Program (ESP) became more widely available, and minor interior/exterior trim updates could have occurred. The 4.7L engine may have received internal updates for reliability or performance.

Production

Manufacturing Location:

Jefferson North Assembly Plant, Detroit, Michigan, USA.

Production Years:

WJ generation: 1999-2004.

🏆 Awards & Recognition

Recognitions

Four Wheeler Of The Year:

The Grand Cherokee (WJ) was awarded Four Wheeler Magazine's 'Four Wheeler of the Year' for 2000, recognizing its off-road capability and overall package.

Motortrend SUV Of The Year:

While not directly for the 2002 model, the Grand Cherokee platform has historically been well-regarded in the SUV segment.