Jeep Grand Cherokee WJ 2002 diesel Service Repair Manual
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🏷️ Basic Information Identification Make: Jeep Model: Grand Cherokee Generation: WJ Year: 2002 Engine Type: Diesel Codes Chassis Code: WJ 👋 Introduction Market Position Segment: Mid-size Luxury SUV Target Audience: Jeep owners seeking detailed repair and maintenance information, DIY enthusiasts, professional mechanics. Competitive Analysis Key Competitors: Ford Explorer, Chevrolet TrailBlazer, Toyota 4Runner, Nissan Pathfinder. Key Features Vehicle Features: Robust off-road capability, comfortable interior, strong towing capacity (diesel variant enhances torque and fuel economy). Manual Value Benefit To Owner: Essential for accurate part ordering, efficient troubleshooting, and performing maintenance and repairs, saving time and money. 📋 Manual Details Coverage Areas Primary Coverage: 2002 Jeep Grand Cherokee WJ Diesel Models Secondary Coverage: Related systems and components applicable to the WJ platform diesel variants. Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (all diesel variants), Transmission (automatic, manual), Drivetrain (transfer case, differentials, axles). Chassis: Suspension (front and rear), Steering, Brakes (ABS, standard). Electrical: Wiring diagrams, lighting, power accessories, ignition system, battery, charging system, starting system. Body And Interior: Body panels, doors, glass, seats, trim, HVAC system, interior components. Diagnostics And Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups. Repair: Component removal, installation, overhaul, and replacement for all major systems. Diagnostics: Step-by-step diagnostic procedures, testing of sensors, actuators, and control modules. Special Tools: Identification and usage of specialized tools required for specific repairs. Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and transmission overhauls. Detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text for quick access to information. Print Quality Print Option: Printable pages for easy workshop use. Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: VM Motori "R" series (e.g., R425 / R428) Displacement: 2.5L / 2.8L (common for European/international markets for this era) Configuration: Inline-4 Cylinder, Turbocharged Diesel Performance Horsepower Range: Approximately 115-140 hp (depending on specific engine variant and tuning) Torque Range: Approximately 245-280 lb-ft (depending on specific engine variant and tuning) Fuel System Injection Type: Common Rail Direct Injection (CRDI) Fuel Type: Diesel Fuel Cooling System Coolant Type: Chrysler/Mopar OAT (5/150,000 Mile Formula) - Orange Coolant Capacity: Approx. 10.0 quarts (9.5 liters) 🔧 Transmission Standard Type: 45RFE / 42RLE 4-speed Automatic Transmission Optional Type: NV3500 5-speed Manual Transmission (less common in diesel variants) Features Automatic Features: Electronically controlled, Overdrive gear, Tow/haul mode. Fluid Specification Automatic Fluid Type: ATF+4 (Chrysler MS-9602) Fluid Capacity Automatic Capacity: Approx. 4.5 quarts (4.3 liters) for dry fill, 11.0 quarts (10.4 liters) total capacity. 📐 Dimensions Exterior Length: Approx. 183.0 inches (4650 mm) Width: Approx. 71.5 inches (1816 mm) Height: Approx. 67.1 inches (1704 mm) Wheelbase Wheelbase: Approx. 116.0 inches (2946 mm) Weights Curb Weight: Approx. 4,400 - 4,700 lbs (2000 - 2130 kg), varies by trim and equipment. Towing Capacity: Up to 5,000 - 7,000 lbs (2268 - 3175 kg), depending on configuration and engine. 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 stars (Driver and Passenger) for 2002 model year. NHTSA Side Impact: 4/5 stars (Front and Rear Passenger) for 2002 model year. Active Features ABS: Standard Anti-lock Braking System (ABS). Traction Control: Optional Traction Control System (TCS). Passive Features Airbags: Driver and front passenger airbags. Optional side curtain airbags may be available on some trims. Seatbelts: Front and rear seat belts with pretensioners for front seats. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional Infinity speaker system. Some models may have available navigation systems. Driver Assistance Cruise Control: Standard cruise control. Connectivity Trailer Tow Prep: Available trailer tow package with wiring harness and receiver hitch. Climate Control HVAC System: Manual or automatic climate control, dual-zone climate control available on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first, using synthetic or synthetic blend oil. Air Filter Replacement: Every 15,000 miles (24,000 km) or annually. Fuel Filter Replacement: Every 30,000 miles (48,000 km) for diesel models. Transmission Fluid Change: Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on driving conditions. Fluid Specifications Engine Oil Viscosity: 0W-40 or 5W-40 Synthetic Diesel Engine Oil (API CI-4 or newer recommended) Brake Fluid Type: DOT 3 or DOT 4. Power Steering Fluid: ATF+4 (Chrysler MS-9602) or specified power steering fluid. Known Issues Common Diesel Issues: Injectors, glow plug system, turbocharger issues, EGR valve problems, potential for head gasket issues on some VM Motori engines if overheated. Common Wj Issues: Cooling system leaks (radiator, water pump, heater core), transfer case chain wear (NV242, NV247), death wobble (front suspension components), power window...
Approx. 4.5 quarts (4.3 liters) for dry fill, 11.0 quarts (10.4 liters) total capacity.
📐 Dimensions
Exterior
Length:
Approx. 183.0 inches (4650 mm)
Width:
Approx. 71.5 inches (1816 mm)
Height:
Approx. 67.1 inches (1704 mm)
Wheelbase
Wheelbase:
Approx. 116.0 inches (2946 mm)
Weights
Curb Weight:
Approx. 4,400 - 4,700 lbs (2000 - 2130 kg), varies by trim and equipment.
Towing Capacity:
Up to 5,000 - 7,000 lbs (2268 - 3175 kg), depending on configuration and engine.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (Driver and Passenger) for 2002 model year.
NHTSA Side Impact:
4/5 stars (Front and Rear Passenger) for 2002 model year.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Optional Traction Control System (TCS).
Passive Features
Airbags:
Driver and front passenger airbags. Optional side curtain airbags may be available on some trims.
Seatbelts:
Front and rear seat belts with pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional Infinity speaker system. Some models may have available navigation systems.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Trailer Tow Prep:
Available trailer tow package with wiring harness and receiver hitch.
Climate Control
HVAC System:
Manual or automatic climate control, dual-zone climate control available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, using synthetic or synthetic blend oil.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Fuel Filter Replacement:
Every 30,000 miles (48,000 km) for diesel models.
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on driving conditions.
Fluid Specifications
Engine Oil Viscosity:
0W-40 or 5W-40 Synthetic Diesel Engine Oil (API CI-4 or newer recommended)
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
ATF+4 (Chrysler MS-9602) or specified power steering fluid.
Known Issues
Common Diesel Issues:
Injectors, glow plug system, turbocharger issues, EGR valve problems, potential for head gasket issues on some VM Motori engines if overheated.
Common Wj Issues:
Cooling system leaks (radiator, water pump, heater core), transfer case chain wear (NV242, NV247), death wobble (front suspension components), power window regulators, rust on rocker panels and rear quarter panels.
📚 Vehicle History
Brand Heritage
Brand Focus:
Jeep is renowned for its off-road capability and rugged utility vehicles, tracing its roots back to World War II.
Model Evolution
Generation Wj:
The WJ generation (1999-2004) represented a significant upgrade over the ZJ, featuring a more modern unibody construction, independent front suspension, and improved interior refinement.
Production
Production Years:
WJ Grand Cherokee production ran from 1999 to 2004.
Assembly Locations:
Jefferson North Assembly Plant, Detroit, Michigan, USA.
Diesel Introduction
Diesel Variant Availability:
Diesel engines were primarily offered in European and international markets for the WJ platform, featuring VM Motori sourced engines.
🏆 Awards & Recognition
Recognitions
SUV Of The Year:
The Grand Cherokee (including WJ generation) has received numerous accolades as a capable and comfortable SUV, often cited for its balance of on-road manners and off-road prowess.
Ratings
Consumer Reports:
Historically, the WJ generation has had mixed reliability ratings, with specific models and engines performing better than others. This manual is crucial for proactive maintenance.
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