2002 Jeep Grand Cherokee Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Grand Cherokee Year: 2002 Codes Chassis Code: WJ Engine Codes: 4.0L (199 CID) - PowerTech I6, 4.7L (287 CID) - PowerTech V8 👋 Introduction Market Position Segment: Mid-size SUV Target Audience: Families, off-road enthusiasts, individuals seeking versatile capability. Competitive Analysis Key Competitors: Ford Explorer, Chevrolet TrailBlazer, Toyota 4Runner, Nissan Pathfinder. Key Features Platform: WJ platform, shared with Mercedes-Benz ML-Class. Capability: Renowned for its off-road prowess, comfortable ride, and towing capacity. Interior: Spacious and refined interior, offering upscale options. 📋 Manual Details Coverage Areas Engine Mechanical: Complete overhaul procedures, component testing, diagnostic charts for all gasoline engines. Engine Electrical: Ignition system, fuel injection, emissions control, charging system, starting system, diagnostic trouble codes (DTCs). Transmission Mechanical: 42RE (4-speed automatic), 45RFE/545RFE (4-speed automatic) overhaul and repair. Transmission Electrical: Transmission control module (TCM) diagnostics, shift solenoids, sensor testing. Drivetrain: Front and rear axle overhauls, differential repair, transfer case (NV242, NV247) service, driveshaft and U-joint replacement. Suspension: Front and rear suspension components, steering system, wheel alignment procedures, shock absorber and spring replacement. Brakes: Front and rear brake systems (disc/drum, disc/disc), ABS system diagnosis and repair, parking brake. Electrical System: Wiring diagrams, lighting, power windows, power locks, wipers, HVAC controls, instrument cluster, interior and exterior lighting. Body And Frame: Body panel repair, door mechanisms, glass replacement, interior trim, structural repair procedures. HVAC: Air conditioning system diagnosis and repair, heater core replacement, climate control module. Fuel System: Fuel pump, fuel injectors, fuel filter replacement, fuel tank service. Emissions: EVAP system, catalytic converter, oxygen sensors, EGR system. Restraints: Airbag system diagnosis, seat belt mechanisms. Diagnostic Trouble Codes: Comprehensive list and troubleshooting procedures for all OBD-II codes. Page Count Total Pages: Approximately 1500-2000 pages (typical for full factory service manuals). Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered All Major Systems: Covers all mechanical, electrical, and body systems of the 2002 Jeep Grand Cherokee. Procedures Included Routine Maintenance: Oil changes, fluid checks, filter replacements, tire rotations, spark plug replacement. Engine Repair: Complete engine overhaul, piston ring replacement, cylinder head service, timing chain/belt replacement (if applicable), valve adjustments. Transmission Repair: Transmission fluid and filter changes, clutch pack replacement, torque converter service, valve body repair. Brake Repair: Brake pad and rotor replacement, brake caliper overhaul, bleeding the brake system, ABS component replacement. Suspension Steering Repair: Ball joint replacement, control arm bushing replacement, tie rod end replacement, power steering pump and rack and pinion service. Electrical Diagnostics: Troubleshooting electrical circuits, diagnosing sensor failures, module testing and replacement. Body Panel Replacement: Procedures for replacing fenders, doors, hoods, tailgates, and associated trim. HVAC System Repair: Refrigerant service, compressor replacement, leak detection, blower motor and resistor replacement. Technical Depth Diagnostics: Detailed diagnostic flowcharts, symptom-based troubleshooting, wiring diagrams for all electrical systems. Rebuilds: Comprehensive rebuild procedures for engines, transmissions, and axles, including torque specifications and clearances. Specifications: Includes all critical torque values, clearances, fluid capacities, and electrical specifications. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Text-searchable for quick information retrieval. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Digital Access: Downloadable digital file, accessible on computers, tablets, and smartphones. Paper Type Digital Medium: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine 1: 4.0L PowerTech I6 Engine 1 Displacement: 3952 cc (241 cubic inches) Engine 1 Configuration: Inline-6 Engine 1 Horsepower: 190 hp @ 4600 rpm Engine 1 Torque: 235 lb-ft @ 3200 rpm Engine 1 Block Material: Cast Iron Engine 1 Head Material: Aluminum Engine 1 Bore X Stroke: 3.88 x 3.41 inches (98.5 mm x 86.7 mm) Engine 1 Compression Ratio: 8.8:1 Engine 1 Fuel System: Sequential Multi-Port Fuel Injection (MPI) Optional Engine Engine 2: 4.7L PowerTech V8 Engine 2 Displacement: 4701 cc (287 cubic inches) Engine 2 Configuration: V8 (90-degree) Engine 2 Horsepower: 235 hp @ 4500 rpm Engine 2 Torque: 325 lb-ft @ 3200 rpm Engine 2 Block Material: Cast Iron Engine 2 Head Material: Aluminum Engine 2 Bore X Stroke: 3.70 x 3.33 inches (94.0 mm x 84.5 mm) Engine 2 Compression Ratio: 9.0:1 Engine 2 Fuel System: Sequential Multi-Port Fuel Injection (MPI) 🔧 Transmission Standard Transmission Type: 42RE 4-Speed Automatic (with 4.0L engine) Optional Transmission Type 2: 45RFE/545RFE 4-Speed Automatic (with 4.7L engine) Features Overdrive: All automatic transmissions feature an overdrive gear for fuel efficiency. Transfer Case Options: NV231 (Part-time Command-Trac), NV247 (Full-time Quadra-Drive II, optional on V8) Transmission Fluid Type 42Re: ATF+4 (MS-9602) Transmission Fluid Type 45Rfe 545Rfe: ATF+4 (MS-9602) Transmission Fluid Capacity 42Re: Approximately 9-10 quarts (dry fill) Transmission Fluid Capacity 45Rfe 545Rfe: Approximately 10-11 quarts (dry fill) 📐 Dimensions Exterior Length: 181.5 inches (4610 mm) Width: 73.5 inches (1867 mm) Height: 66.7 inches (1694 mm) Wheelbase: 104.7 inches (2659 mm) Ground Clearance: Approx. 8.7 inches (221 mm) Approach...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Grand Cherokee

Year:

Codes

Chassis Code:

Engine Codes:

4.0L (199 CID) - PowerTech I6, 4.7L (287 CID) - PowerTech V8

👋 Introduction

Market Position

Segment:

Mid-size SUV

Target Audience:

Families, off-road enthusiasts, individuals seeking versatile capability.

Competitive Analysis

Key Competitors:

Ford Explorer, Chevrolet TrailBlazer, Toyota 4Runner, Nissan Pathfinder.

Key Features

Platform:

WJ platform, shared with Mercedes-Benz ML-Class.

Capability:

Renowned for its off-road prowess, comfortable ride, and towing capacity.

Interior:

Spacious and refined interior, offering upscale options.

📋 Manual Details

Coverage Areas

Engine Mechanical:

Complete overhaul procedures, component testing, diagnostic charts for all gasoline engines.

Engine Electrical:

Ignition system, fuel injection, emissions control, charging system, starting system, diagnostic trouble codes (DTCs).

Transmission Mechanical:

42RE (4-speed automatic), 45RFE/545RFE (4-speed automatic) overhaul and repair.

Transmission Electrical:

Transmission control module (TCM) diagnostics, shift solenoids, sensor testing.

Drivetrain:

Front and rear axle overhauls, differential repair, transfer case (NV242, NV247) service, driveshaft and U-joint replacement.

Suspension:

Front and rear suspension components, steering system, wheel alignment procedures, shock absorber and spring replacement.

Brakes:

Front and rear brake systems (disc/drum, disc/disc), ABS system diagnosis and repair, parking brake.

Electrical System:

Wiring diagrams, lighting, power windows, power locks, wipers, HVAC controls, instrument cluster, interior and exterior lighting.

Body And Frame:

Body panel repair, door mechanisms, glass replacement, interior trim, structural repair procedures.

HVAC:

Air conditioning system diagnosis and repair, heater core replacement, climate control module.

Fuel System:

Fuel pump, fuel injectors, fuel filter replacement, fuel tank service.

Emissions:

EVAP system, catalytic converter, oxygen sensors, EGR system.

Restraints:

Airbag system diagnosis, seat belt mechanisms.

Diagnostic Trouble Codes:

Comprehensive list and troubleshooting procedures for all OBD-II codes.

Page Count

Total Pages:

Approximately 1500-2000 pages (typical for full factory service manuals).

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

All Major Systems:

Covers all mechanical, electrical, and body systems of the 2002 Jeep Grand Cherokee.

Procedures Included

Routine Maintenance:

Oil changes, fluid checks, filter replacements, tire rotations, spark plug replacement.

Engine Repair:

Complete engine overhaul, piston ring replacement, cylinder head service, timing chain/belt replacement (if applicable), valve adjustments.

Transmission Repair:

Transmission fluid and filter changes, clutch pack replacement, torque converter service, valve body repair.

Brake Repair:

Brake pad and rotor replacement, brake caliper overhaul, bleeding the brake system, ABS component replacement.

Suspension Steering Repair:

Ball joint replacement, control arm bushing replacement, tie rod end replacement, power steering pump and rack and pinion service.

Electrical Diagnostics:

Troubleshooting electrical circuits, diagnosing sensor failures, module testing and replacement.

Body Panel Replacement:

Procedures for replacing fenders, doors, hoods, tailgates, and associated trim.

HVAC System Repair:

Refrigerant service, compressor replacement, leak detection, blower motor and resistor replacement.

Technical Depth

Diagnostics:

Detailed diagnostic flowcharts, symptom-based troubleshooting, wiring diagrams for all electrical systems.

Rebuilds:

Comprehensive rebuild procedures for engines, transmissions, and axles, including torque specifications and clearances.

Specifications:

Includes all critical torque values, clearances, fluid capacities, and electrical specifications.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Text-searchable for quick information retrieval.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Digital Access:

Downloadable digital file, accessible on computers, tablets, and smartphones.

Paper Type

Digital Medium:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine 1:

4.0L PowerTech I6

Engine 1 Displacement:

3952 cc (241 cubic inches)

Engine 1 Configuration:

Inline-6

Engine 1 Horsepower:

190 hp @ 4600 rpm

Engine 1 Torque:

235 lb-ft @ 3200 rpm

Engine 1 Block Material:

Cast Iron

Engine 1 Head Material:

Aluminum

Engine 1 Bore X Stroke:

3.88 x 3.41 inches (98.5 mm x 86.7 mm)

Engine 1 Compression Ratio:

8.8:1

Engine 1 Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Optional Engine

Engine 2:

4.7L PowerTech V8

Engine 2 Displacement:

4701 cc (287 cubic inches)

Engine 2 Configuration:

V8 (90-degree)

Engine 2 Horsepower:

235 hp @ 4500 rpm

Engine 2 Torque:

325 lb-ft @ 3200 rpm

Engine 2 Block Material:

Cast Iron

Engine 2 Head Material:

Aluminum

Engine 2 Bore X Stroke:

3.70 x 3.33 inches (94.0 mm x 84.5 mm)

Engine 2 Compression Ratio:

9.0:1

Engine 2 Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

🔧 Transmission

Standard

Transmission Type:

42RE 4-Speed Automatic (with 4.0L engine)

Optional

Transmission Type 2:

45RFE/545RFE 4-Speed Automatic (with 4.7L engine)

Features

Overdrive:

All automatic transmissions feature an overdrive gear for fuel efficiency.

Transfer Case Options:

NV231 (Part-time Command-Trac), NV247 (Full-time Quadra-Drive II, optional on V8)

Transmission Fluid Type 42Re:

ATF+4 (MS-9602)

Transmission Fluid Type 45Rfe 545Rfe:

ATF+4 (MS-9602)

Transmission Fluid Capacity 42Re:

Approximately 9-10 quarts (dry fill)

Transmission Fluid Capacity 45Rfe 545Rfe:

Approximately 10-11 quarts (dry fill)

📐 Dimensions

Exterior

Length:

181.5 inches (4610 mm)

Width:

73.5 inches (1867 mm)

Height:

66.7 inches (1694 mm)

Wheelbase:

104.7 inches (2659 mm)

Ground Clearance:

Approx. 8.7 inches (221 mm)

Approach Angle:

Approx. 37.3 degrees

Departure Angle:

Approx. 29.7 degrees

Breakover Angle:

Approx. 21.6 degrees

Weights

Curb Weight:

Approx. 4,000 - 4,500 lbs (1814 - 2041 kg), varies by engine and trim.

Gross Vehicle Weight Rating Gvwr:

Approx. 5,600 - 5,800 lbs (2540 - 2630 kg)

Towing Capacity:

Up to 5,000 lbs (2268 kg) with optional towing package.

Payload Capacity:

Approx. 1,100 - 1,200 lbs (500 - 544 kg)

Interior

Seating Capacity:

5 passengers

Cargo

Cargo Volume Behind Rear Seat:

Approx. 37.7 cubic feet (1067 liters)

Cargo Volume With Rear Seat Folded:

Approx. 70.9 cubic feet (2008 liters)

Wheel Specs

Wheel Bolt Pattern:

5 x 4.5 inches (5x114.3 mm)

Standard Wheel Size:

16-inch alloy wheels

Optional Wheel Size:

17-inch alloy wheels

Tire Specs

Standard Tire Size:

P235/70R16

Optional Tire Size:

P235/65R17

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 stars (2002)

NHTSA Front Impact Passenger:

4 stars (2002)

NHTSA Side Impact Front Seat:

5 stars (2002)

NHTSA Side Impact Rear Seat:

4 stars (2002)

IIHS Front Offset Score:

Good (2002)

IIHS Side Impact Score:

Acceptable (2002)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models.

Electronic Stability Control:

Not typically standard on 2002 models.

Passive Features

Airbags:

Standard front driver and passenger airbags, optional side curtain airbags on select trims.

Seatbelts:

3-point seatbelts for all seating positions, pretensioners for front seats.

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with CD player, optional premium audio systems with amplifier and subwoofer.

Navigation:

Optional factory-installed GPS navigation system.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional rear parking assist sensors.

Connectivity

Auxiliary Input:

Not typically standard; aftermarket solutions often available.

Remote Keyless Entry:

Optional remote keyless entry system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for exact recommendation).

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving environment.

Spark Plug Replacement 4.0L:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Spark Plug Replacement 4.7L:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km) or as per manual, especially if towing.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km).

Fluid Specifications

Engine Oil 4.0L:

SAE 5W-30 (API Service SM or higher), capacity approx. 6 quarts (5.7 liters).

Engine Oil 4.7L:

SAE 5W-30 or 5W-20 (API Service SM or higher), capacity approx. 6.5 quarts (6.2 liters).

Coolant:

Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, or equivalent.

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF+4 (MS-9602) or equivalent power steering fluid.

Known Issues

Cylinder Head Cracks 4.7L:

The 4.7L V8 is known for a potential for cylinder head cracking, especially in earlier models and if overheated. Regular coolant checks and addressing overheating are crucial.

Transmission Issues:

Some issues with the 42RE transmission, particularly regarding harsh shifting or slipping, can occur. Regular fluid changes are key.

Cooling System Leaks:

Common to find leaks in hoses, radiator, or water pump over time. Overheating can exacerbate other issues.

Interior Rattles:

Typical for SUVs of this era, various interior trim pieces can develop rattles.

Climate Control Actuators:

Malfunctioning blend door actuators can lead to temperature or airflow control issues.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long-standing reputation for ruggedness and off-road capability dating back to WWII.

Model Evolution

Wj Generation:

The WJ generation (1999-2004) represented a significant refinement over the previous ZJ Grand Cherokee, with a unibody construction and more premium features, influenced by Mercedes-Benz ownership.

2002 Updates:

Minor updates for 2002 included revised suspension tuning and potentially new feature availability.

Production

Manufacturing Location:

Jefferson North Assembly, Detroit, Michigan, USA

Production Years:

1999-2004 (WJ Generation)

🏆 Awards & Recognition

Recognitions

Kbb Ratings:

Consistently rated well by Kelley Blue Book for its capability and value in its segment during its production run.

Four Wheel Drive Magazine Awards:

Often cited for its off-road capabilities and four-wheel-drive systems by off-road focused publications.