Jeep CHEROKEE KJ 4X4 (RHD) 2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Platform Code: KJ Generation Code: KJ Model Year: 2003 Drivetrain: 4x4 Steering Position: Right-Hand Drive (RHD) 👋 Introduction Market Position Market Segment:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Platform Code:

Generation Code:

Model Year:

Drivetrain:

Steering Position:

Right-Hand Drive (RHD)

👋 Introduction

Market Position

Market Segment:

Compact SUV / Sport Utility Vehicle

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra, Land Rover Freelander (at the time of its release)

Key Features

Jeep Heritage:

The KJ Cherokee represents Jeep's foray into the smaller, more urban-friendly SUV segment while retaining some of its off-road DNA.

Vehicle Platform:

Based on the DaimlerChrysler KJ platform, sharing components with other Chrysler Group vehicles.

Manual Utility

Target Audience:

DIY mechanics, automotive technicians, fleet maintenance personnel, and Jeep enthusiasts looking for in-depth repair and maintenance information.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Emissions, Diagnostics, Troubleshooting, Maintenance

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive factory service manuals)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Detailed coverage of the 2.4L I4 and 3.7L V6 engines, including diagnosis, repair, and overhaul. Also covers NV244 transfer case and Dana 30/44 axles.

Chassis:

Comprehensive coverage of front and rear suspension (independent front suspension with coil springs), steering system (power rack and pinion), and braking system (front disc/rear drum or disc).

Electrical:

Extensive wiring diagrams, fuse box layouts, component testing, diagnosis of charging system, starting system, ignition system, lighting, and onboard electronic modules.

Comfort And Convenience:

Includes sections on HVAC system operation and repair, interior trim removal and installation, power accessories (windows, locks, mirrors), and seat mechanisms.

Procedures Included

Maintenance:

Routine maintenance procedures such as oil changes, filter replacements, fluid checks and changes, spark plug replacement, and belt inspection/replacement.

Repair And Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for major vehicle systems.

Diagnostics And Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, including symptom identification, diagnostic trouble codes (DTCs), and component testing.

Technical Specifications:

Provides torque specifications, clearances, fluid types and capacities, wiring color codes, and diagnostic data for various components and systems.

Technical Depth

Depth Of Coverage:

Comprehensive, covering from basic scheduled maintenance to advanced engine and transmission overhauls, electrical system diagnosis, and bodywork repair.

📊 Manual Specifications

File Format

File Format:

Portable Document Format (PDF)

Print Quality

Print Quality:

High-resolution scans, allowing for clear reproduction of diagrams, illustrations, and text.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Searchability

Searchable Text:

Typically Yes (for digitally created PDFs), allowing for quick keyword searches of specific topics.

⚙️ Engine Specifications

Primary Engine

Engine Code 2 4L:

ED3 (2.4L DOHC 16-valve Inline-4 'PowerTech')

Engine Code 3 7L:

EP2 (3.7L SOHC 12-valve V6 'PowerTech')

Performance 2 4L

Displacement 2 4L:

2429 cc

Bore X Stroke 2 4L:

87.5 mm x 100.0 mm

Compression Ratio 2 4L:

9.1:1

Horsepower 2 4L:

150 hp @ 5200 rpm

Torque 2 4L:

169 lb-ft @ 4000 rpm

Performance 3 7L

Displacement 3 7L:

3701 cc

Bore X Stroke 3 7L:

87.5 mm x 103.0 mm

Compression Ratio 3 7L:

9.6:1

Horsepower 3 7L:

205 hp @ 5200 rpm

Torque 3 7L:

235 lb-ft @ 4000 rpm

Fuel System

Fuel Induction:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Management

ECM Type:

Manufacturer-specific Engine Control Module (ECM) - covered in electrical section

🔧 Transmission

Standard Transmission

Manual Transmission:

5-speed manual (Getrag 238), typically paired with the 2.4L engine.

Optional Transmission

Automatic Transmission:

4-speed automatic (Chrysler 42RLE), standard with the 3.7L V6 and optional with the 2.4L I4.

Transfer Case

Transfer Case Type:

NV244 Command-Trac (full-time 4WD with selectable 2WD)

Fluid Specifications

Automatic Transmission Fluid:

Chrysler ATF+4 (MS-9602)

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 synthetic gear lubricant

Transfer Case Fluid:

NV244 specific lubricant (often Mercon V or equivalent)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2690 mm (106.1 inches)

Length:

Approx. 4450 mm (175.2 inches)

Width:

Approx. 1820 mm (71.7 inches)

Height:

Approx. 1640 mm (64.6 inches) without roof rails

Ground Clearance:

Approx. 200 mm (7.9 inches) depending on tire size and suspension setup

Weights

Curb Weight 2 4L:

Approx. 1600-1700 kg

Curb Weight 3 7L:

Approx. 1700-1850 kg

Towing Capacity:

Up to 2000 kg (4400 lbs) with factory tow package

Wheels And Tires

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Standard Tire Size:

P215/75R16, P235/65R17

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

4 stars (driver), 4 stars (passenger)

IIHS Frontal Offset Test:

Good (for models equipped with side airbags)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models.

Passive Features

Airbags:

Standard front airbags, optional front side-impact airbags.

Rollover Protection:

Enhanced body structure for rollover resistance.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional Infinity premium sound system.

Navigation:

No factory integrated navigation system available for the 2003 model year.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Auxiliary Input:

No factory auxiliary audio input (typically requires aftermarket modification).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months, whichever comes first (check manual for specific oil type and capacity).

Air Filter Replacement:

Every 15,000-30,000 miles, or as needed based on driving conditions.

Spark Plug Replacement 2 4L:

Every 100,000 miles (platinum or iridium type)

Spark Plug Replacement 3 7L:

Every 100,000 miles (platinum or iridium type)

Coolant Flush:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil 2 4L:

API SN or newer, SAE 5W-30, Capacity: 4.5 Quarts (4.3 Liters)

Engine Oil 3 7L:

API SN or newer, SAE 5W-30, Capacity: 5 Quarts (4.7 Liters)

Coolant:

Chrysler HOAT (Hybrid Organic Additive Technology) coolant, blue or pink color. Capacity: 7.1 Quarts (6.7 Liters) for 2.4L, 8.7 Quarts (8.2 Liters) for 3.7L.

Known Issues

Common Problem Headgasket:

The 2.4L engine (ED3) is known for potential head gasket failures, particularly around the intake manifold crossover pipe.

Common Problem Transfer Case Motors:

Actuator motors for the 4WD system can fail, leading to loss of 4WD engagement.

Common Problem Interior Rattles:

Interior panels and components can develop rattles and squeaks over time.

Common Problem Suspension Components:

Wear on ball joints, tie rod ends, and control arm bushings can lead to steering looseness and clunks.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

The Jeep brand has a storied history in off-road vehicles, tracing its roots back to World War II.

Model Evolution

Kj Introduction:

The KJ Cherokee was introduced for the 2002 model year as a successor to the XJ Cherokee in most markets, though it was positioned differently, focusing more on comfort and on-road manners.

Kj Facelift:

The 2003 model year represents the early production phase of the KJ Cherokee before its first significant facelift in 2005.

Production

Production Period:

2002-2007

Production Location

Manufacturing Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

4X4 Magazine Ranking:

Often recognized for its capable 4x4 system and off-road potential within its segment, though generally not a class leader in refinement.