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Jeep CHEROKEE KJ 4X4 (RHD) 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: KJ Year: 2002 Drivetrain: 4X4 Market: Right-Hand Drive (RHD) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle...
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Jeep CHEROKEE KJ 4X4 (RHD) 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Model Code:
KJ
Year:
2002
Drivetrain:
4X4
Market:
Right-Hand Drive (RHD)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-Road Vehicle
Jeep Brand Heritage:
Jeep is renowned for its off-road prowess, ruggedness, and iconic styling, with a history dating back to World War II.
Competitive Analysis
Competitors 2002:
Ford Escape, Toyota RAV4, Honda CR-V, Nissan Xterra, Land Rover Freelander.
Key Features Vehicle
Key Selling Points:
Renowned Jeep off-road capability, compact and maneuverable size, comfortable ride for its class, distinctive styling.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
PDF
Page Count
Estimated Page Count:
1500+
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine overhaul, diagnostics, tuning, fuel system, ignition system, cooling system, lubrication system, emissions control.
Transmission:
Service and repair of automatic and manual transmissions, transfer case, driveline components, clutch (if applicable).
Suspension And Steering:
Front and rear suspension systems, steering components, power steering system, wheel alignment procedures.
Brakes:
Hydraulic brake system, ABS, parking brake, disc and drum brake overhaul, bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system, starting system, lighting system, power windows, power locks, accessories, fuses, relays, diagnostic trouble codes (DTCs).
Body And Chassis:
Body panel repair, doors, windows, interior trim, exterior trim, frame repair, rust prevention.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections, brake pad replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault finding charts, symptom-based diagnosis.
Repair:
Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Diagnostics:
On-Board Diagnostics (OBD-II) system, sensor testing, actuator testing, scanner usage.
Technical Depth
Depth Level:
Comprehensive and in-depth, covering everything from basic maintenance to complete engine and transmission rebuilds.
Target Audience:
Professional mechanics, DIY enthusiasts, and Jeep owners seeking detailed repair and maintenance guidance.
📊 Manual Specifications
File Format
File Type:
Digital PDF
Searchable Text:
Yes
Printable:
Yes
Image Quality:
High-resolution scans of original factory diagrams and illustrations.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Name:
2.4L PowerTech I4
Engine Code:
EDK
Displacement:
2429 cc (148.3 cubic inches)
Bore X Stroke:
87.5 mm x 100 mm (3.44 in x 3.94 in)
Compression Ratio:
9.1:1
Horsepower:
154 hp @ 5200 rpm
Torque:
225 Nm (166 lb-ft) @ 3800 rpm
Valve Train:
SOHC (Single Overhead Camshaft), 16 valves
Performance
0-60 Mph Estimate:
Approx. 10.5 - 11.5 seconds (varies with transmission and configuration)
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Tank Capacity:
65.1 Liters (17.2 US Gallons)
🔧 Transmission
Standard
Transmission Type Standard:
4-Speed Automatic Transmission
Optional
Transmission Type Optional:
5-Speed Manual Transmission
Features
Transfer Case:
Command-Trac NV130 (standard 4WD system)
Automatic Transmission Fluid Type:
ATF+4 (Chrysler Material Standard MS-9602)
Manual Transmission Fluid Type:
API GL-5, SAE 75W-90 Gear Oil
📐 Dimensions
Exterior
Length:
4425 mm (174.2 in)
Width:
1830 mm (72.0 in)
Height:
1733 mm (68.2 in) (with roof rails)
Wheelbase:
2690 mm (106.0 in)
Ground Clearance:
Approx. 196 mm (7.7 in)
Approach Angle:
Approx. 38 degrees
Departure Angle:
Approx. 32 degrees
Breakover Angle:
Approx. 24 degrees
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Weights
Curb Weight:
Approx. 1650 kg (3638 lbs)
Gross Vehicle Weight Rating Gvwr:
Approx. 2160 kg (4762 lbs)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating Estimate:
Likely 3-star or 4-star (typical for SUVs of this era, specific ratings vary)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags.
Seatbelts:
Three-point front and rear seat belts, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM/CD player with optional premium sound system and subwoofer. Auxiliary inputs were less common in early models.
Driver Assistance
Stability Control:
Electronic Stability Program (ESP) was introduced as an option later in the KJ's lifecycle, not standard on all 2002 models.
Connectivity
Connectivity Options:
Limited by modern standards. Basic connectivity might include power outlets for accessories. Uconnect hands-free was not available for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval Gas:
Every 12,000 km (7,500 miles) or 6 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Every 24,000 km (15,000 miles) or 12 months.
Coolant Flush:
Every 100,000 km (60,000 miles) or 5 years, whichever comes first.
Transmission Fluid Change Auto:
Every 60,000 km (37,500 miles) or 3 years.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 (API certified, Chrysler MS-6395)
Coolant Spec:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Green (50/50 mix with distilled water)
Brake Fluid Spec:
DOT 3 or DOT 4
Known Issues
Common Problems:
Cracked cylinder heads (especially 3.7L V6, but can affect 2.4L), transfer case issues (especially NV140/NV235), differential seal leaks, AC evaporator leaks, some electrical gremlins.
📚 Vehicle History
Brand Heritage
Jeep Founding:
Jeep's origins trace back to the Willys MB Jeep used by the U.S. Army in World War II.
Model Evolution
Kj Generation Introduction:
The KJ Cherokee (Liberty in North America) was introduced for the 2002 model year, replacing the XJ Cherokee in most markets. It marked a move to a more body-on-frame chassis design, differentiating it from unibody competitors.
Production
Kj Production Years:
2002-2007
Manufacturing Locations:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Jeep Brand Awards:
Jeep brand consistently ranks high in off-road capability and owner satisfaction in specific segments.
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