Jeep Cherokee KJ 2002-2007 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: KJ Generation: Second Generation (KJ) Production Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Code: KJ 👋 Introduction...

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类型: Car

斯库: 448318

标签: 2002 2003 2004 2005 2006 2007 Car Cars Cherokee KJ Jeep Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Model Code:

Generation:

Second Generation (KJ)

Production Years Covered:

2002, 2003, 2004, 2005, 2006, 2007

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road capable vehicle

Target Audience:

Owners seeking to perform their own maintenance and repairs, independent repair shops, and automotive enthusiasts.

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra, Subaru Forester.

Key Features

Vehicle Strengths:

Jeep's legendary off-road capability, comfortable ride for its class, available powerful engines, and distinctive styling.

Manual Value Proposition:

Empowers owners and technicians with detailed, accurate information to maintain, diagnose, and repair the Jeep Cherokee KJ efficiently and effectively.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF)

Page Count

Page Count:

Comprehensive (Specific number not provided in product info, but typical for workshop manuals)

📖 Manual Coverage

Systems Covered

Engine:

Detailed coverage of all engine types offered for the KJ Cherokee during these model years, including diagnosis, repair, overhaul, and component specifics.

Transmission:

Includes repair and maintenance procedures for both automatic and manual transmissions, including torque converters, clutch systems, and gearboxes.

Drivetrain:

Comprehensive information on 4WD/AWD systems (Command-Trac, Selec-Trac), transfer cases, differentials, driveshafts, and axles.

Suspension:

Front and rear suspension systems, shock absorbers, struts, control arms, bushings, and alignment specifications.

Steering:

Power steering system diagnosis and repair, steering rack, tie rods, and steering column components.

Brakes:

Front and rear brake systems (disc/drum), ABS operation and diagnosis, brake fluid, master cylinder, calipers, and parking brake.

Electrical:

Extensive coverage of the vehicle's electrical system, including battery, charging system, starting system, lighting, ignition, instrument cluster, and wiring diagrams.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, repair, refrigerant handling, and component replacement.

Bodywork:

Body panel repair, doors, windows, locks, hinges, bumpers, and interior trim removal/installation.

Chassis:

Frame and chassis component inspection and repair.

Safety Systems:

Airbag system diagnosis and repair, seat belt mechanisms.

Procedures Included

Maintenance:

Regular scheduled maintenance, fluid changes, filter replacements, and inspections.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, and fault code interpretation.

Repair:

Step-by-step repair procedures for virtually all mechanical and electrical components.

Overhaul:

Complete engine and transmission rebuild procedures.

Diagnostics:

Advanced diagnostic techniques using specialized tools and scan data.

Component Replacement:

Detailed instructions for replacing individual components.

Specifications:

Torque specifications, clearances, alignments, and other critical data.

Technical Depth

Depth:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission overhauls.

Diagnostic Tools:

Information on essential diagnostic tools and procedures for modern vehicles.

Wiring Diagrams:

Detailed electrical wiring diagrams for all systems, crucial for troubleshooting.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format) - Common for digital service manuals

Searchability:

Likely text-searchable PDF, allowing for quick information retrieval.

Print Quality

Print Readability:

Designed for clear printing, with legible text and diagrams.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Chrysler/Jeep EER (PowerTech) and PSA (VM Motori) Diesel

Gasoline Engine 1:

2.4L (2429cc) DOHC I4 (GEMA/World I4)

Gasoline Engine 1 Power:

Approx. 147-154 hp @ 5200-5800 rpm

Gasoline Engine 1 Torque:

Approx. 165-171 lb-ft @ 4000 rpm

Gasoline Engine 2:

3.7L (3701cc) SOHC V6 (EER/PowerTech)

Gasoline Engine 2 Power:

Approx. 205-215 hp @ 5500-5800 rpm

Gasoline Engine 2 Torque:

Approx. 235-240 lb-ft @ 4000 rpm

Diesel Engine 1:

2.8L (2777cc) CRD DOHC I4 Turbo Diesel (VM Motori)

Diesel Engine 1 Power:

Approx. 150-163 hp @ 3800 rpm

Diesel Engine 1 Torque:

Approx. 260-295 lb-ft @ 1800-2000 rpm

Fuel System

Fuel Delivery Gasoline:

Sequential Multi-port Fuel Injection (MPI)

Fuel Delivery Diesel:

Common Rail Direct Injection (CRD)

Recommended Fuel Gasoline:

87 Octane Unleaded Gasoline (check owner's manual for specific octane requirements)

Recommended Fuel Diesel:

ULSD (Ultra-Low Sulfur Diesel)

🔧 Transmission

Standard

Transmission Type Gasoline:

4-speed automatic (42RLE)

Transmission Type Diesel:

4-speed automatic (42RLE)

Optional

Transmission Type Gasoline Manual:

5-speed manual (NV3500/NV1500)

Transmission Type Diesel Manual:

6-speed manual (NSG370)

Features

Transfer Case Options:

Command-Trac NV231-J (Part-time 4WD), Selec-Trac NV242 (Full-time 4WD)

Automatic Transmission Fluid:

ATF+4 (MS-9602)

Manual Transmission Fluid:

Refer to manual for specific fluid type (e.g., Mopar Manual Transmission Fluid or equivalent)

📐 Dimensions

Exterior

Wheelbase:

104.1 inches (2644 mm)

Length:

175.3 inches (4453 mm)

Width:

71.7 inches (1821 mm)

Height:

67.5 inches (1715 mm)

Ground Clearance:

Approx. 8.1 inches (206 mm) (Varies by model and tires)

Weights

Curb Weight:

Approx. 3500-3900 lbs (1588-1769 kg) (Varies by engine and drivetrain)

Gross Vehicle Weight Rating Gvwr:

Approx. 4800-5000 lbs (2177-2268 kg)

Cargo

Cargo Volume Behind Rear Seat:

Approx. 30.0 cubic feet (0.85 cubic meters)

Cargo Volume With Rear Seat Folded:

Approx. 69.0 cubic feet (1.95 cubic meters)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Crash Test:

Good (refer to NHTSA for specific year and test)

NHTSA Frontal Passenger Crash Test:

Good (refer to NHTSA for specific year and test)

NHTSA Side Driver Crash Test:

Good (refer to NHTSA for specific year and test)

NHTSA Side Rear Passenger Crash Test:

Good (refer to NHTSA for specific year and test)

IIHS Frontal Offset Crash Test:

Good (refer to IIHS for specific year and test)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Electronic Stability Control:

Available Electronic Stability Program (ESP)

Passive Features

Airbags Front:

Standard driver and front passenger airbags

Airbags Side:

Available front side-impact airbags

Seatbelts:

3-point front and rear seatbelts, pretensioners and load limiters for front seats.

💡 Technology Features

Infotainment

Audio System:

Available AM/FM stereo with CD player, optional Infinity speaker system, satellite radio preparation.

Navigation:

Optional factory navigation system was available on higher trim levels.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Tire Pressure Monitoring System:

Optional Tire Pressure Monitoring System (TPMS).

Connectivity

Auxiliary Input:

Available auxiliary audio input jack on later models or through aftermarket solutions.

Power Outlets:

Standard 12V power outlets.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Typically every 3,000-6,000 miles or 3-6 months, depending on driving conditions (refer to manual for exact recommendation based on oil type).

Oil Change Interval Diesel:

Typically every 5,000-7,500 miles or 6 months for diesel engines (refer to manual for exact recommendation).

Engine Air Filter Replacement:

Typically every 15,000-30,000 miles or as needed based on inspection.

Cabin Air Filter Replacement:

Typically every 12,000-15,000 miles or annually.

Spark Plug Replacement Gasoline:

Varies by plug type; typically 30,000-100,000 miles (refer to manual for specific engine and plug type).

Coolant Flush:

Typically every 30,000-60,000 miles or 2-5 years (refer to manual for specific coolant type and interval).

Fluid Specifications

Engine Oil Gasoline:

SAE 5W-30 is common for both engines. Refer to manual and oil cap for exact specification and API service classification.

Engine Oil Diesel:

Specific diesel engine oil meeting API CJ-4 or equivalent, viscosity typically 5W-40 or 15W-40. Crucial to check manual.

Coolant:

Chrysler HOAT (Hybrid Organic Acid Technology) OAT coolant or equivalent (typically pink or orange).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to reservoir cap).

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent DEXRON III/MERCON ATF.

Known Issues

Common Concern 1:

Worn front suspension components (ball joints, control arm bushings), leading to steering looseness and tire wear.

Common Concern 2:

Failure of the Sentry Key Immobilizer System (SKIM) causing no-start conditions.

Common Concern 3:

Issues with the automatic transmission (42RLE), particularly solenoid pack failures or torque converter issues.

Common Concern 4:

Diesel engine specific issues can include turbocharger problems, injector issues, and EGR valve clogging.

Common Concern 5:

Water pump leaks and radiator issues.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep is a brand with a long and storied history, dating back to World War II, renowned for its off-road prowess and ruggedness.

Model Evolution

Kj Introduction:

The KJ Cherokee was introduced for the 2002 model year, replacing the XJ Cherokee. It adopted a more modern, unibody construction with a distinct, rounded styling compared to its predecessor.

Kj Facelift:

A minor facelift occurred for the 2005 model year, featuring updated styling, interior enhancements, and powertrain revisions.

Production

Manufacturing Locations:

Primarily produced in Toledo, Ohio, USA.

Production End Date:

Production of the KJ Cherokee ended in 2007, succeeded by the KK Cherokee.

🏆 Awards & Recognition

Recognitions

Off Road Capability Recognition:

Consistently recognized for its off-road prowess within its class, often outperforming many front-wheel-drive biased competitors.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by year and powertrain; specific data should be consulted from reliable consumer resources.

Certifications

Emissions Standards:

Designed to meet U.S. EPA and California ARB emissions standards for its model years.