Jeep Grand CHEROKEE WG 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Grand Cherokee Year: 2002 Codes Platform Code: WJ 👋 Introduction Market Position Segment: Mid-size Luxury SUV Competitive Analysis Key Competitors 2002: Ford Explorer, Toyota 4Runner, Chevrolet Blazer, Nissan Pathfinder, Land Rover Discovery. Key Features Platform Design: WJ platform, unibody construction with integrated body-frame, providing a balance of on-road comfort and off-road capability. Powertrain Options: Renowned for its robust engine options and capable four-wheel-drive systems. Luxury Appointments: Offered a more refined interior and a higher level of amenities compared to its predecessors. 📋 Manual Details Coverage Areas Coverage Breadth: Comprehensive service and repair for all major vehicle systems. Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanics: Detailed diagnostics, repair, overhaul for 4.0L I6 and 4.7L V8 engines. Engine Management: PCM operation, sensor data, fuel injection, ignition timing, emissions control. Transmission Manual: NV3500 5-speed manual transmission: overhaul, diagnostics, clutch system. Transmission Automatic: 42RE, 45RFE/4545RFE automatic transmissions: diagnostics, repair, fluid service, torque converter. Drivetrain 4Wd: NV242 Selec-Trac, NV247 Command-Trac transfer cases: operation, maintenance, repair, NVH troubleshooting. Axles Differentials: Dana 30 front axle, Dana 35c rear axle (standard), Chrysler 8.25 rear axle (optional): differential overhaul, gear pattern adjustment, axle shaft replacement. Suspension: Front: Independent Front Suspension (IFS) with upper and lower control arms, coil springs. Rear: Solid axle with multi-link setup, coil springs. Includes diagnostics, alignment procedures, component replacement. Steering: Power steering system: pump, rack and pinion, hydraulic lines, troubleshooting, fluid service. Brakes Front: Vented disc brakes: pads, rotors, calipers, hydraulic lines, ABS system integration. Brakes Rear: Disc brakes (most models): pads, rotors, calipers, parking brake mechanism, ABS integration. Electrical System: 12V battery, charging system (alternator), starting system (starter motor). Lighting System: Headlights, taillights, interior lighting, fog lamps, bulb replacement procedures. HVAC System: Air conditioning, heating, ventilation, climate control module, blower motor, refrigerant service. Body Exterior: Body panels, doors, tailgate, bumpers, glass, trim, hinges, latches, seals, alignment. Body Interior: Dashboard, seats, upholstery, trim panels, headliner, sound insulation. Restraint Systems: Airbag system, seat belts, SRS module diagnostics and replacement. Infotainment Audio: Radio, CD player, speaker systems, antenna, wiring. Instrument Panel Gauges: Speedometer, tachometer, fuel gauge, temperature gauge, warning lamps, cluster diagnostics. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Procedures Included Scheduled Maintenance: Oil change, filter replacement, fluid checks, tire rotation, brake inspection, belt replacement. Troubleshooting Diagnostics: Step-by-step diagnostic flowcharts for common drivability, electrical, and mechanical issues. Engine Rebuild: Detailed procedures for cylinder head removal/installation, piston and ring replacement, bearing service, crankshaft inspection. Transmission Overhaul: Complete disassembly, inspection, component replacement, and reassembly of automatic and manual transmissions. Brake System Repair: Calibrating ABS, bleeding brake lines, replacing pads, rotors, calipers, and brake hoses. Suspension Component Replacement: Control arm bushings, ball joints, tie rod ends, shock absorbers, springs. HVAC Component Replacement: Compressor, evaporator, condenser, expansion valve, accumulator, blend door actuators. Electrical Component Replacement: Alternator, starter, battery, fuel pump, ignition coils, sensors, modules. Body Panel Alignment Repair: Door adjustment, tailgate alignment, bumper replacement, fender repair. Technical Depth Depth Level: Factory-level repair and diagnostic procedures, including torque specifications, clearances, and alignment data. Diagnostic Tools: Information on using diagnostic scan tools (e.g., DRB III) for advanced troubleshooting. Special Tools: Identification and usage of specialized tools required for specific procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality Print Readability: High-resolution scans with clear diagrams and text, suitable for printing. Binding Type Binding Format: Digital (not applicable for physical binding) Paper Type Paper Quality: Digital (not applicable for physical paper type) ⚙️ Engine Specifications Primary Engine Engine 1 Type: 4.0L Inline 6-Cylinder (PowerTech I6) Engine 1 Displacement: 3956 cc (241.4 cu in) Engine 1 Bore X Stroke: 98.5 mm x 86.6 mm (3.88 in x 3.41 in) Engine 1 Compression Ratio: 8.8:1 Engine 1 Horsepower: 190 hp @ 4600 rpm (approx.) Engine 1 Torque: 235 lb-ft @ 3200 rpm (approx.) Engine 1 Block Material: Cast Iron Engine 1 Head Material: Aluminum Alloy Engine 1 Valvetrain: Overhead Valve (OHV), 2 valves per cylinder Engine 1 Fuel System: Electronic Fuel Injection (MPI) Optional Engine Engine 2 Type: 4.7L V8 (PowerTech V8) Engine 2 Displacement: 4701 cc (286.9 cu in) Engine 2 Bore X Stroke: 93.0 mm x 86.0 mm (3.66 in x 3.39 in) Engine 2 Compression Ratio: 9.0:1 Engine 2 Horsepower: 235 hp @ 4500 rpm (approx.) Engine 2 Torque: 300 lb-ft @ 3200 rpm (approx.) Engine 2 Block Material: Aluminum Alloy Engine 2 Head Material: Aluminum Alloy Engine 2 Valvetrain: Overhead Valve (OHV), 2 valves per cylinder Engine 2 Fuel System: Electronic Fuel Injection (MPI) 🔧 Transmission Standard Transmission Standard Type: 42RE 4-speed Automatic Optional Transmission Optional Type: 45RFE/4545RFE 4-speed Automatic (later models used NAG1 5-speed) Transmission Manual Optional Type: NV3500 5-speed Manual...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Grand Cherokee

Year:

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Mid-size Luxury SUV

Competitive Analysis

Key Competitors 2002:

Ford Explorer, Toyota 4Runner, Chevrolet Blazer, Nissan Pathfinder, Land Rover Discovery.

Key Features

Platform Design:

WJ platform, unibody construction with integrated body-frame, providing a balance of on-road comfort and off-road capability.

Powertrain Options:

Renowned for its robust engine options and capable four-wheel-drive systems.

Luxury Appointments:

Offered a more refined interior and a higher level of amenities compared to its predecessors.

📋 Manual Details

Coverage Areas

Coverage Breadth:

Comprehensive service and repair for all major vehicle systems.

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Detailed diagnostics, repair, overhaul for 4.0L I6 and 4.7L V8 engines.

Engine Management:

PCM operation, sensor data, fuel injection, ignition timing, emissions control.

Transmission Manual:

NV3500 5-speed manual transmission: overhaul, diagnostics, clutch system.

Transmission Automatic:

42RE, 45RFE/4545RFE automatic transmissions: diagnostics, repair, fluid service, torque converter.

Drivetrain 4Wd:

NV242 Selec-Trac, NV247 Command-Trac transfer cases: operation, maintenance, repair, NVH troubleshooting.

Axles Differentials:

Dana 30 front axle, Dana 35c rear axle (standard), Chrysler 8.25 rear axle (optional): differential overhaul, gear pattern adjustment, axle shaft replacement.

Suspension:

Front: Independent Front Suspension (IFS) with upper and lower control arms, coil springs. Rear: Solid axle with multi-link setup, coil springs. Includes diagnostics, alignment procedures, component replacement.

Steering:

Power steering system: pump, rack and pinion, hydraulic lines, troubleshooting, fluid service.

Brakes Front:

Vented disc brakes: pads, rotors, calipers, hydraulic lines, ABS system integration.

Brakes Rear:

Disc brakes (most models): pads, rotors, calipers, parking brake mechanism, ABS integration.

Electrical System:

12V battery, charging system (alternator), starting system (starter motor).

Lighting System:

Headlights, taillights, interior lighting, fog lamps, bulb replacement procedures.

HVAC System:

Air conditioning, heating, ventilation, climate control module, blower motor, refrigerant service.

Body Exterior:

Body panels, doors, tailgate, bumpers, glass, trim, hinges, latches, seals, alignment.

Body Interior:

Dashboard, seats, upholstery, trim panels, headliner, sound insulation.

Restraint Systems:

Airbag system, seat belts, SRS module diagnostics and replacement.

Infotainment Audio:

Radio, CD player, speaker systems, antenna, wiring.

Instrument Panel Gauges:

Speedometer, tachometer, fuel gauge, temperature gauge, warning lamps, cluster diagnostics.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Procedures Included

Scheduled Maintenance:

Oil change, filter replacement, fluid checks, tire rotation, brake inspection, belt replacement.

Troubleshooting Diagnostics:

Step-by-step diagnostic flowcharts for common drivability, electrical, and mechanical issues.

Engine Rebuild:

Detailed procedures for cylinder head removal/installation, piston and ring replacement, bearing service, crankshaft inspection.

Transmission Overhaul:

Complete disassembly, inspection, component replacement, and reassembly of automatic and manual transmissions.

Brake System Repair:

Calibrating ABS, bleeding brake lines, replacing pads, rotors, calipers, and brake hoses.

Suspension Component Replacement:

Control arm bushings, ball joints, tie rod ends, shock absorbers, springs.

HVAC Component Replacement:

Compressor, evaporator, condenser, expansion valve, accumulator, blend door actuators.

Electrical Component Replacement:

Alternator, starter, battery, fuel pump, ignition coils, sensors, modules.

Body Panel Alignment Repair:

Door adjustment, tailgate alignment, bumper replacement, fender repair.

Technical Depth

Depth Level:

Factory-level repair and diagnostic procedures, including torque specifications, clearances, and alignment data.

Diagnostic Tools:

Information on using diagnostic scan tools (e.g., DRB III) for advanced troubleshooting.

Special Tools:

Identification and usage of specialized tools required for specific procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval.

Print Quality

Print Readability:

High-resolution scans with clear diagrams and text, suitable for printing.

Binding Type

Binding Format:

Digital (not applicable for physical binding)

Paper Type

Paper Quality:

Digital (not applicable for physical paper type)

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

4.0L Inline 6-Cylinder (PowerTech I6)

Engine 1 Displacement:

3956 cc (241.4 cu in)

Engine 1 Bore X Stroke:

98.5 mm x 86.6 mm (3.88 in x 3.41 in)

Engine 1 Compression Ratio:

8.8:1

Engine 1 Horsepower:

190 hp @ 4600 rpm (approx.)

Engine 1 Torque:

235 lb-ft @ 3200 rpm (approx.)

Engine 1 Block Material:

Cast Iron

Engine 1 Head Material:

Aluminum Alloy

Engine 1 Valvetrain:

Overhead Valve (OHV), 2 valves per cylinder

Engine 1 Fuel System:

Electronic Fuel Injection (MPI)

Optional Engine

Engine 2 Type:

4.7L V8 (PowerTech V8)

Engine 2 Displacement:

4701 cc (286.9 cu in)

Engine 2 Bore X Stroke:

93.0 mm x 86.0 mm (3.66 in x 3.39 in)

Engine 2 Compression Ratio:

9.0:1

Engine 2 Horsepower:

235 hp @ 4500 rpm (approx.)

Engine 2 Torque:

300 lb-ft @ 3200 rpm (approx.)

Engine 2 Block Material:

Aluminum Alloy

Engine 2 Head Material:

Aluminum Alloy

Engine 2 Valvetrain:

Overhead Valve (OHV), 2 valves per cylinder

Engine 2 Fuel System:

Electronic Fuel Injection (MPI)

🔧 Transmission

Standard

Transmission Standard Type:

42RE 4-speed Automatic

Optional

Transmission Optional Type:

45RFE/4545RFE 4-speed Automatic (later models used NAG1 5-speed)

Transmission Manual Optional Type:

NV3500 5-speed Manual (less common)

Features

Transmission Features:

Overdrive gear, torque converter lock-up, electronic control (on later models).

📐 Dimensions

Exterior

Wheelbase:

116.1 inches (2950 mm)

Length:

189.4 inches (4811 mm)

Width:

74.7 inches (1897 mm)

Height:

67.4 inches (1712 mm)

Ground Clearance:

8.7 inches (221 mm)

Weights

Curb Weight Min:

4,500 lbs (2041 kg)

Curb Weight Max:

5,000 lbs (2268 kg)

Gross Vehicle Weight Rating Gvwr:

6,000 lbs (2722 kg) - 6,500 lbs (2948 kg) depending on configuration

Cargo

Cargo Volume Behind 2Nd Row:

39.0 cu ft (1104 L)

Cargo Volume Max:

77.0 cu ft (2180 L)

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

Good (for models with side airbags)

NHTSA Passenger Front Impact:

Good (for models with side airbags)

Active Features

Standard Anti-lock Braking System (4-wheel disc brakes)

Traction Control:

Available

Electronic Stability Control:

Not widely available on this model year.

Passive Features

Airbags Front:

Standard dual front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

Three-point seat belts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Infotainment System Availability:

Optional premium audio systems, CD players, and navigation systems were available.

Driver Assistance

Cruise Control:

Standard feature.

Parking Assist:

Rear parking sensors available on higher trims.

Connectivity

Connectivity Options:

Limited to basic audio auxiliary inputs or optional satellite radio features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Engine Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months.

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months, especially under severe driving conditions.

Spark Plug Replacement 4.0L:

Every 100,000 miles (160,000 km) (long-life platinum)

Spark Plug Replacement 4.7L:

Every 60,000 miles (96,000 km) (platinum)

Fluid Specifications

Engine Oil Type:

API SN, SAE 5W-30 (for both engines)

Engine Oil Capacity 4.0L:

5 Quarts (4.7 Liters)

Engine Oil Capacity 4.7L:

6 Quarts (5.7 Liters)

Transmission Fluid Type 42Re/45Rfe:

ATF+4 (Mopar)

Transmission Fluid Capacity 42Re:

Approx. 7.5 Quarts (7.1 Liters) for refill

Transmission Fluid Capacity 45Rfe/4545Rfe:

Approx. 9.5 Quarts (9.0 Liters) for refill

Transfer Case Fluid Type:

NV242: Mopar Transfer Case Lubricant or equivalent. NV247: Mopar NV247 Transfer Case Lubricant or equivalent.

Differential Fluid Type Front/Rear:

API GL-5, SAE 80W-90 Gear Lubricant (check for limited-slip additive if equipped)

Coolant Type:

Chrysler Long Life HOAT (Hybrid Organic Acid Technology), Orange

Power Steering Fluid Type:

ATF+4 (Mopar) or equivalent

Known Issues

Common Issue Death Wobble:

Front-end vibration, often referred to as 'Death Wobble,' typically caused by worn steering components (track bar, ball joints, tie rod ends) and suspension bushings.

Common Issue Heater Core:

Heater core leaks, often manifesting as a sweet smell inside the cabin and condensation on the windshield.

Common Issue Ignition Coils:

Failure of ignition coils, particularly on the 4.7L V8, leading to misfires and rough running.

Common Issue Radiator:

Cracked plastic end tanks on the radiator leading to coolant leaks.

Common Issue Manifold Cracks 4.7L:

Exhaust manifold cracks on the 4.7L V8 engine, causing exhaust leaks and ticking noises.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's long-standing reputation for off-road capability and ruggedness.

Model Evolution

Wj Generation Introduction:

The WJ Grand Cherokee replaced the ZJ generation and was produced from 1999 to 2004.

Wj Key Innovations:

Introduction of independent front suspension for improved on-road manners, availability of the 4.7L V8 engine, and more premium interior appointments.

Production

Manufacturing Locations:

Detroit, Michigan, USA (Jefferson North Assembly Plant)

Production Years Wj:

1999-2004

🏆 Awards & Recognition

Recognitions

Award Off Road Capability:

Consistently recognized for its off-road prowess and trail capability, a hallmark of the Grand Cherokee lineage.

Award Luxury SUV:

Often cited for its blend of luxury and utility within the SUV segment for its era.