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Jeep LIBERTY KJ Service Repair Workshop Manual 2002

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🏷️ Basic Information Identification Make: Jeep Model: Liberty Generation Code: KJ Model Year: 2002 Codes Platform Code: KJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Sport Utility Vehicle...
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Sku: 289809
Jeep LIBERTY KJ Service Repair Workshop Manual 2002
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Liberty
Generation Code:
KJ
Model Year:
2002
Codes
Platform Code:
KJ
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Sport Utility Vehicle
Jeep Brand Positioning:
The Liberty (KJ) positioned Jeep's compact offering, emphasizing rugged capability and iconic Jeep styling within the growing SUV market.
Competitive Analysis
Key Competitors:
Ford Escape, Toyota RAV4, Honda CR-V, Nissan Xterra, Chevrolet Tracker/Suzuki Vitara.
Key Features
Off Road Capability:
Renowned Jeep off-road prowess, available with 4x4 systems (e.g., Command-Trac, Select-Trac), solid rear axle (on some configurations) for improved articulation.
Design Styling:
Distinctive Jeep seven-slot grille, rugged exterior styling, relatively upright stance.
Manual Value Proposition:
Provides the same level of detail and accuracy as used by dealership technicians, enabling comprehensive DIY repairs and maintenance.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
All Models & All Repairs A-Z
Page Count
Estimated Page Count:
Detailed page count unavailable in provided info, but typical factory service manuals for this era range from 1500-3000+ pages.
Manual Type
Type:
Factory Service/Workshop Manual
Language
Language:
English
Format
Format:
Likely a digital format (PDF) or bound printed manual, mirroring dealer technician resources.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, powertrain control module (PCM).
Transmission:
Automatic transmission (e.g., 42RLE), manual transmission (e.g., NV1500), transfer case operation, driveline.
Chassis:
Suspension (front and rear), steering system, brake system (ABS, hydraulic, parking brake), wheels and tires.
Electrical:
Battery, charging system, starting system, lighting, instrument cluster, body control module (BCM), power distribution, audio system, power accessories (windows, locks, mirrors).
Body And Interior:
Body panels, doors, windows, interior trim, seats, HVAC (heating, ventilation, air conditioning), body sealant and protection.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid checks and changes, filter replacements, lubrication points, tire rotation and pressure.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit diagrams and testing.
Repair:
Component removal and installation, engine rebuild procedures, transmission overhaul, suspension and steering component replacement, brake caliper and rotor replacement, electrical component repair.
Specifications:
Torque specifications for all fasteners, fluid capacities, electrical specifications, dimensional data.
Technical Depth
Depth:
Factory-level detail, including diagnostic procedures, component testing, specifications, and repair instructions suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, allowing for searching, printing, and digital access. Quality often includes high-resolution diagrams and clear text.
Print Quality
Diagram Clarity:
Expected to have clear, detailed diagrams, schematics, and illustrations crucial for accurate repairs.
Binding Type
Physical Binding:
If printed, would typically be a durable bound format, suitable for shop use. Digital format ensures easy access and searchability.
Paper Type
Physical Paper:
If printed, likely on durable, high-quality paper designed to withstand workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline 1:
2.4L PowerTech (ED1) I4
Engine Displacement Gasoline 1:
2429 cc (148.2 cubic inches)
Engine Configuration Gasoline 1:
Inline 4-cylinder
Horsepower Gasoline 1:
Approx. 150 HP @ 5200 RPM
Torque Gasoline 1:
Approx. 165 lb-ft @ 4000 RPM
Optional Engine
Engine Code Gasoline 2:
3.7L PowerTech V6 (EHB)
Engine Displacement Gasoline 2:
3701 cc (225.8 cubic inches)
Engine Configuration Gasoline 2:
V6
Horsepower Gasoline 2:
Approx. 205 HP @ 5200 RPM
Torque Gasoline 2:
Approx. 235 lb-ft @ 4000 RPM
Engine Code Diesel:
2.5L VM Motori (425) CRD Diesel (RPO Code: ENF)
Engine Displacement Diesel:
2499 cc (152.5 cubic inches)
Engine Configuration Diesel:
Inline 4-cylinder Turbo Diesel
Horsepower Diesel:
Approx. 140 HP @ 4000 RPM
Torque Diesel:
Approx. 255 lb-ft @ 1800 RPM
Fuel System
Gasoline Fuel Delivery:
Multi-port Fuel Injection (MPI)
Diesel Fuel Delivery:
Common Rail Direct Injection (CRDI)
🔧 Transmission
Standard
Manual Transmission Option:
NV1500 5-speed manual transmission (often paired with the 2.4L I4)
Optional
Automatic Transmission Option:
42RLE 4-speed automatic transmission (often paired with the 3.7L V6)
Features
Transfer Case Options:
Command-Trac NV131 (part-time 2-speed transfer case) or Select-Trac NV242 (full-time 2-speed transfer case with 2WD, 4WD Full-Time, 4WD Part-Time, Neutral, Low range options).
Gear Ratios Nv1500:
Specific gear ratios available in the manual, crucial for performance and fuel economy calculations.
Gear Ratios 42Rle:
Specific gear ratios and lock-up clutch engagement speeds available in the manual.
📐 Dimensions
Exterior
Wheelbase:
104.2 inches (2647 mm)
Length:
Approx. 173.5 inches (4407 mm)
Width:
Approx. 71.3 inches (1811 mm)
Height:
Approx. 67.0 inches (1702 mm) (without roof rails)
Weights
Curb Weight Start:
Approx. 3,600 lbs (1633 kg) for 2.4L 2WD models.
Curb Weight End:
Up to approx. 4,100 lbs (1860 kg) for 3.7L V6 4WD models.
Towing Capacity:
Typically rated up to 3,500 lbs (1588 kg) with the optional towing package.
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4-star rating for the 2002 model year.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Optional traction control system (TCS) available on some models.
Passive Features
Airbags:
Front airbags for driver and passenger; optional side airbags were available.
Seatbelts:
Three-point seat belts in all seating positions; pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory radio with AM/FM, CD player. Upgraded Infinity sound systems were available.
Navigation:
Optional factory navigation system was available on higher trim levels.
Driver Assistance
Cruise Control:
Standard or optional cruise control system.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors were common features, especially on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Typically every 3,000 to 7,500 miles or 6 to 12 months, depending on driving conditions and oil type (refer to manual for exact recommendations).
Oil Change Interval Diesel:
Often recommended every 5,000 to 7,500 miles for diesel engines, with specific attention to filter replacement.
Tire Rotation:
Recommended every 5,000 to 7,500 miles.
Spark Plug Replacement Gasoline:
Intervals vary by spark plug type, often between 30,000 and 100,000 miles for platinum or iridium plugs.
Transmission Fluid Change Interval:
Generally recommended every 30,000 to 60,000 miles, depending on usage and fluid type.
Fluid Specifications
Engine Oil Type Gasoline:
Typically SAE 5W-30 or 10W-30 for gasoline engines (refer to owner's manual or manual for precise API/ILSAC specifications).
Engine Oil Type Diesel:
Specific diesel engine oil grades (e.g., API CJ-4 or equivalent) recommended for the 2.5L CRD engine.
Coolant:
Mopar OAT (Organic Additive Technology) coolant or equivalent, typically a 50/50 mix with distilled water.
Transmission Fluid Automatic:
ATF+4 (Automatic Transmission Fluid Type 9602) is specified for the 42RLE transmission.
Transmission Fluid Manual:
Manual transmission fluid specifications will be detailed in the manual, often a GL-4 or GL-5 gear oil.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues Powertrain:
Oil cooler leaks (especially on V6), potential for valve cover gasket leaks, exhaust manifold cracks (on some V6 engines).
Common Issues Transmission:
42RLE transmission can sometimes develop shifting issues or torque converter problems if not properly maintained.
Common Issues Suspension Steering:
Ball joint wear, tie rod end wear, and front control arm bushings can be common wear items on higher mileage vehicles.
Common Issues Electrical:
Window regulator failures, HVAC blower motor resistor failures, and dashboard warning light illumination can occur.
Common Issues Diesel:
CRD models can experience issues with fuel injectors, glow plugs, and the EGR system if not maintained.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Built upon Jeep's reputation for off-road capability and ruggedness, leveraging the Wrangler and Grand Cherokee DNA.
Model Evolution
Introduction Year:
The KJ Liberty was introduced for the 2002 model year, replacing the Jeep Cherokee (XJ) in Jeep's North American lineup.
Platform Sharing:
Shared its platform with the Dodge Nitro (second generation) and some Mercedes-Benz platforms of the era, reflecting DaimlerChrysler's corporate structure.
Production
Manufacturing Location:
Primarily manufactured at the Toledo North Complex in Toledo, Ohio, USA.
Production Years:
2002-2007 (KJ generation)
🏆 Awards & Recognition
Recognitions
Jeep Brand Recognition:
Jeep vehicles generally receive recognition for their off-road capabilities and ruggedness.
Ratings
Consumer Reports Ratings:
Ratings varied for the Liberty KJ, with some models showing average or below-average reliability based on consumer surveys in certain years.
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