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Jeep LIBERTY KJ Complete Workshop Repair Manual 2002

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🏷️ Basic Information Identification Make: Jeep Model: Liberty KJ Year: 2002 👋 Introduction Market Position Market Position: The Jeep Liberty KJ (2002-2007) occupied the compact/mid-size SUV segment, known for its...
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Jeep LIBERTY KJ Complete Workshop Repair Manual 2002
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Liberty KJ
Year:
2002
👋 Introduction
Market Position
Market Position:
The Jeep Liberty KJ (2002-2007) occupied the compact/mid-size SUV segment, known for its 'Jeep' off-road capability and distinctive styling, appealing to buyers seeking utility and a more rugged image than typical crossovers.
Competitive Analysis
Competitive Analysis:
Competed with vehicles like the Ford Explorer Sport Trac, Toyota 4Runner, Nissan Xterra, and Chevrolet TrailBlazer. Key differentiators were its more compact footprint compared to some rivals and its signature Jeep brand heritage and off-road prowess.
Key Features
Key Features:
Body-on-frame construction, available Selec-Trac NV242 transfer case with 2WD and 4WD Full-Time modes, Command-Trac NV136 for part-time 4WD, rugged exterior styling, versatile cargo space, and a comfortable ride for its class.
📋 Manual Details
Coverage Areas
Coverage Areas:
All aspects of service, repair, maintenance, diagnostics, and troubleshooting for the Jeep Liberty KJ model.
Page Count
Page Count:
Extensive (typical workshop manuals of this caliber exceed 2000 pages, though an exact count is not provided, the term 'in depth' implies comprehensive coverage).
Manual Type
Manual Type:
Complete Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
Digital Download (PC, MAC, Tablets & Smartphones Compatible)
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, engine performance, fuel system, ignition system, exhaust system, cooling system, lubrication system, transmission (automatic and manual), drivetrain, transfer case, axles, suspension (front and rear), steering system, braking system (ABS, drum, disc), electrical system (charging, starting, lighting, body controls, power accessories), HVAC system, emissions control, body and frame, interior components, exterior trim, body hardware, diagnostics, troubleshooting, wiring diagrams.
Procedures Included
Procedures Included:
Routine maintenance, preventative maintenance, diagnostic procedures, component removal and installation, repair procedures, overhaul procedures, adjustments, torque specifications, wiring harness repair, diagnostic trouble code (DTC) interpretation and resolution, fluid changes, filter replacements, brake bleeding, clutch adjustment, suspension alignment specifications.
Technical Depth
Technical Depth:
Professional quality, in-depth. Covers everything from basic fluid checks and tire rotations to complete engine and transmission rebuilds, complex electrical diagnostics, and body panel repairs.
📊 Manual Specifications
File Format
File Format:
PDF (optimized for digital viewing across multiple devices)
Print Quality
Print Quality:
High-resolution, clear text and diagrams suitable for printing individual pages.
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
2.4L PowerTech I4 (G4CS)
Primary Engine Details
Displacement:
2429 cc (148 cubic inches)
Bore X Stroke:
92.0 mm x 90.5 mm (3.62 in x 3.56 in)
Compression Ratio:
9.1:1
Horsepower Net:
150 hp @ 5200 rpm (approximate)
Torque Net:
170 lb-ft @ 4000 rpm (approximate)
Optional Engine
Optional Engine:
3.7L PowerTech V6 (EGV)
Optional Engine Details
Displacement:
3701 cc (226 cubic inches)
Bore X Stroke:
87.1 mm x 101.0 mm (3.43 in x 3.98 in)
Compression Ratio:
9.7:1
Horsepower Net:
210 hp @ 5200 rpm (approximate)
Torque Net:
235 lb-ft @ 4000 rpm (approximate)
Fuel System
Fuel System:
Multi-port Fuel Injection (MPI)
Fuel Type
Fuel Type:
Unleaded gasoline (87 octane recommended)
Emission Control
Emission Control:
Catalytic converter, oxygen sensors, EGR system (depending on market).
🔧 Transmission
Standard Transmission
Standard Transmission:
4-speed automatic (42RLE)
Optional Transmission
Optional Transmission:
5-speed manual (NV1500)
Transmission Features
Transmission Features:
Electronically controlled overdrive, torque converter lock-up clutch for improved fuel efficiency.
Transfer Case
Transfer Case Optional:
Selec-Trac NV242 (2WD, 4WD Full-Time, 4WD Part-Time, 4WD Low) or Command-Trac NV136 (2WD, 4WD Part-Time, 4WD Low).
Fluid Specification
Automatic Transmission Fluid:
Chrysler ATF+4 (MS-9602)
Manual Transmission Fluid:
API GL-5, SAE 75W-90 synthetic gear lubricant
Transfer Case Fluid
Transfer Case Fluid:
Mopar NV242 Transfer Case Lubricant (or equivalent satisfying MS-1870, typically SAE 75W-90 gear lubricant)
📐 Dimensions
Exterior Length
Length:
4428 mm (174.3 in)
Exterior Width
Width:
1830 mm (72.0 in)
Exterior Height
Height:
1755 mm (69.1 in)
Wheelbase
Wheelbase:
2644 mm (104.1 in)
Ground Clearance
Ground Clearance:
Approx. 203 mm (8.0 in) for 4WD models (varies slightly by tire and suspension)
Curb Weight
Curb Weight:
1700-1850 kg (3750-4080 lbs) depending on configuration
Cargo Volume
Cargo Volume Behind Rear Seat:
Approx. 773 liters (27.3 cubic feet)
Cargo Volume Seats Folded:
Approx. 1980 liters (70.0 cubic feet)
🛡️ Safety Features
Ratings
NHTSA Front Driver Impact:
Good (for the 2002 model year)
NHTSA Front Passenger Impact:
Good (for the 2002 model year)
NHTSA Side Driver Impact:
Not rated or marginal (side airbags were optional)
NHTSA Side Rear Passenger Impact:
Not rated or marginal (side airbags were optional)
Active Features
Active Features:
Four-wheel Anti-lock Braking System (ABS), Traction Control System (TCS - often paired with 4WD models), Electronic Stability Program (ESP - became more common in later KJ models).
Passive Features
Passive Features:
Driver and front passenger airbags, front seatbelt pretensioners, LATCH child seat anchor system.
💡 Technology Features
Infotainment
Infotainment System:
Base models featured an AM/FM/CD player with 4-6 speakers. Higher trims offered an upgraded Infinity sound system with a subwoofer and an in-dash CD changer. Uconnect hands-free communication was not widely available in the early KJ models.
Driver Assistance
Driver Assistance:
ABS and optional Traction Control System were primary driver assistance features. ESP became more prevalent on later models or as part of premium packages.
Connectivity
Connectivity:
Limited to auxiliary input jacks for audio in later iterations of the KJ model. No USB ports or Bluetooth audio streaming were standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first, using recommended oil type and filter.
Tire Rotation Interval:
Every 7,500 miles (12,000 km)
Engine Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving conditions.
Cabin Air Filter Replacement:
Every 15,000 to 20,000 miles (24,000 to 32,000 km) or annually.
Spark Plug Replacement:
I4: 100,000 miles (160,000 km) for iridium plugs; V6: 100,000 miles (160,000 km) for iridium plugs.
Fluid Specifications
Engine Oil Capacity:
2.4L I4: 4.5 quarts (4.3 L); 3.7L V6: 5.5 quarts (5.2 L), with filter change.
Engine Oil Type:
SAE 5W-30 synthetic blend or full synthetic (API SN or equivalent).
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) OAT coolant (pink) or equivalent, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (check specific vehicle recommendations).
Known Issues
Known Issues:
Common issues include: radiator leaks, power steering pump failures, death wobble (steering shimmy at speed), differential pinion seal leaks, minor electrical gremlins (window motors, power locks), potential catalytic converter issues, and sometimes transmission solenoid failures on automatic transmissions. The transfer case actuator on Selec-Trac models can also be a point of concern.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Jeep, a division of Chrysler (now Stellantis), has a rich history dating back to World War II with the Willys MB. Known for its off-road capability and ruggedness, the brand has a loyal following and iconic models like the Wrangler and Grand Cherokee.
Model Evolution
Model Evolution:
The KJ Liberty was introduced for the 2002 model year, replacing the Jeep Cherokee (XJ) in the North American lineup. It was based on the KJ platform, which shared some components with the Dodge Dakota. It received a facelift for the 2005 model year with updated styling and features. The Liberty KJ was produced until 2007, succeeded by the KK Liberty.
Production
Production Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Recognitions:
While the KJ Liberty itself didn't win numerous industry awards as a specific model, it benefited from the Jeep brand's reputation for off-road capability. It was generally well-received for its styling and utility within its segment during its production run.
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