Jeep LIBERTY KJ Factory Service Repair Manual 2002

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🏷️ Basic Information Identification Make: Jeep Model: Liberty Generation: KJ (First Generation) Model Year: 2002 Codes Chassis Code: KJ Production Code: KJ 👋 Introduction Market Position Vehicle Segment: Compact SUV...

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Mots clés: 2002 Car Cars Jeep LIBERTY KJ Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Liberty

Generation:

KJ (First Generation)

Model Year:

Codes

Chassis Code:

Production Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Sport Utility Vehicle

Jeep Heritage:

Carries the Jeep legacy of off-road capability and ruggedness

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra (in its segment)

Key Features

Design:

Distinctive Jeep styling, boxy proportions, vertical grille, round headlights

Capability:

Available four-wheel drive systems, good ground clearance for its class

Versatility:

Practical interior, cargo space suitable for active lifestyles

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual & Supplemental Manual

Language:

English

Format:

Digital (Likely PDF, searchable text)

Full Coverage:

Yes, comprehensive

Supplemental Engines:

2.4L Gas Engine

Page Count

Estimated Page Count:

1000+ (Typical for full factory service manuals of this era)

📖 Manual Coverage

Systems Covered

Powertrain Engine:

Engine disassembly, assembly, diagnostics, repair, tuning for 2.4L Gas (4-Cyl) and likely 3.7L V6 (provided in main manual)

Powertrain Transmission:

Manual and Automatic Transmission service, diagnostics, repair, and overhaul (specific models likely covered, e.g., NV1500, NV3500, 42RLE)

Drivetrain:

Four-wheel drive system (Command-Trac/Selec-Trac), differentials, axles, driveshafts, U-joints, CV joints

Suspension:

Front and rear suspension components, alignment, shock absorbers, springs, control arms, bushings

Steering:

Power steering system, steering column, steering gear/rack and pinion, tie rods

Brakes:

Front and rear brake systems (disc/drum configurations), hydraulic system, ABS, parking brake

Electrical System:

Battery, charging system (alternator), starting system (starter), ignition system, lighting, accessories, fuses, relays

Body And Chassis:

Body panels, doors, windows, interior trim, bumpers, frame structure, corrosion protection

HVAC:

Heating, ventilation, and air conditioning system, components, refrigerant handling, diagnostics

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel lines, evaporative emission control (EVAP)

Cooling System:

Radiator, water pump, thermostat, coolant hoses, cooling fan

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, exhaust pipes

Restraints:

Airbag system (SRS), seat belts, pretensioners

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), troubleshooting charts, scan tool usage

Procedures Included

Maintenance:

Routine maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups

Assembly Disassembly:

Step-by-step instructions for component removal and installation

Repair:

Detailed repair procedures for all major systems

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides

Rebuilds:

Complete engine and transmission overhaul procedures

Specifications:

Torque specifications, clearances, adjustments, tolerances

Wiring Diagrams:

Complete electrical system wiring diagrams

Technical Depth

Depth Level:

Expert/Professional Level

Detail Level:

Extensive, including detailed diagrams, exploded views, and technical notes

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text for quick information retrieval

Print Quality

Resolution:

High-resolution scans, ensuring clarity of diagrams and text

Readability:

Optimized for screen viewing and printing

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Name:

2.4L PowerTech (GEMA I4) - Supplemental Engine

Engine Configuration:

Inline 4-Cylinder

Displacement:

2351 cc (143.5 cu in)

Bore X Stroke:

87.0 mm x 97.0 mm (3.43 in x 3.82 in)

Compression Ratio:

9.5:1

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Horsepower Rated:

154 hp @ 6000 rpm (approx.)

Torque Rated:

167 lb-ft @ 4000 rpm (approx.)

Engine Alternatives

Optional Engine:

3.7L PowerTech V6 (Supplied in main manual)

V6 Displacement:

3701 cc (225.9 cu in)

V6 Horsepower:

205 hp @ 5200 rpm (approx.)

V6 Torque:

235 lb-ft @ 4000 rpm (approx.)

🔧 Transmission

Standard

Transmission Type I4:

5-Speed Manual (e.g., NV1500, NV3500)

Optional

Transmission Type Auto I4:

4-Speed Automatic (e.g., 42RLE)

Transmission Type V6:

4-Speed Automatic (42RLE) standard with V6

Features

Transfer Case Options:

Command-Trac NV235 (part-time 4WD) or Selec-Trac NV244 (full-time 4WD)

Fluid Specifications

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 (check specific manual for exact spec)

Automatic Transmission Fluid:

Chrysler ATF+4 (Mopar Specification)

📐 Dimensions

Exterior

Wheelbase:

104.7 inches (2659 mm)

Length:

173.5 inches (4407 mm)

Width:

72.6 inches (1844 mm)

Height:

67.7 inches (1720 mm)

Ground Clearance:

Approx. 8.3 inches (211 mm) (4WD models)

Weights

Curb Weight I4:

Approx. 3500-3700 lbs (1588-1678 kg)

Curb Weight V6:

Approx. 3800-4000 lbs (1724-1814 kg)

Towing Capacity:

Up to 3500 lbs (1588 kg) (when properly equipped)

Wheels Tires

Wheel Bolt Pattern:

5x4.5 (5x114.3 mm)

Standard Tire Size:

P225/75R16 (Commonly)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

4/5 stars (for 2WD and 4WD variants, often rated higher for 4WD)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional or standard depending on trim/options

Passive Features

Airbags:

Driver and front passenger airbags, optional side airbags

Seat Belts:

Three-point seat belts, front seat pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player, optional Infinity speaker system, optional Sirius satellite radio

Driver Assistance

Cruise Control:

Standard

Connectivity

Power Windows:

Standard on most trims

Power Locks:

Standard on most trims

Remote Keyless Entry:

Optional

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Engine Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Cabin Air Filter:

Replace every 15,000-30,000 miles, depending on environment.

Spark Plugs:

Typically every 60,000-100,000 miles for modern plugs (refer to manual for exact type and interval).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic, 40,000-80,000 miles for manual (depends on usage and fluid type).

Fluid Specifications

Engine Oil Type:

5W-30 or 10W-30 (API SN or equivalent, consult manual for specific viscosity based on temperature)

Coolant:

Chrysler HOAT (Hybrid Organic Acid Technology) Long Life Antifreeze/Coolant, 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 (check manual for specific type)

Power Steering Fluid:

ATF+4 or specific power steering fluid as per manual

Known Issues

Common Problems:

Rear main seal leaks, differential seal leaks, transfer case issues, HVAC blend door actuator failures, oil filter housing leaks, head gasket concerns (especially on early 3.7L V6).

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Part of Chrysler's Jeep division, known for its off-road prowess since the 1940s.

Model Evolution

Launch Year:

Platform Origin:

Based on the Jeep Commander (XK) concept, shared platform with Mitsubishi Pajero Sport (DaimlerChrysler's alliance with Mitsubishi at the time).

Product Line:

Introduced to fill a gap between the smaller Jeep Cherokee (XJ) and the larger Grand Cherokee (WJ), offering a more traditional SUV experience than some unibody competitors.

Production

Production Plant:

Toledo North Assembly Plant, Toledo, Ohio, USA

Production Years:

2002-2007