Jeep Cherokee KJ 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: KJ Year: 2004 Generation Generation Code: KJ Generation Years: 2002-2007 Codes Chassis Code: KJ 👋 Introduction Market Position Segment: Compact...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Model Code:

Year:

Generation

Generation Code:

Generation Years:

2002-2007

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Off-road enthusiasts, adventure seekers, practical SUV buyers.

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Nissan X-Trail (previous generation).

Differentiation:

Stronger off-road capability compared to most rivals, Jeep's established brand heritage.

Key Features

Off Road Capability:

Command-Trac NV242 part-time 2-speed transfer case, available Selec-Trac NV242 full-time 4WD system, solid rear axle (on some configurations), good ground clearance.

Body On Frame Construction:

Offers robustness for off-road use (though KJ is unibody, this is often a Jeep expectation).

Practicality:

Sufficient passenger and cargo space for its class.

📋 Manual Details

Coverage Areas

Engine:

Transmission Automatic:

Transmission Manual:

Drivetrain:

Suspension:

Brakes:

Steering:

Electrical System:

Body And Chassis:

HVAC:

Interior Trim:

Diagnostics:

Troubleshooting:

Wiring Diagrams:

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

File Format

File Type:

Searchable:

Yes (typically, depending on PDF origin)

Printable:

Print Quality

Quality:

High-resolution (for clear diagrams and text)

Binding Type

Binding:

Not applicable (digital format)

Paper Type

Paper:

Not applicable (digital format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed procedures for disassembly, inspection, assembly, and repair of all engine components.

Engine Management:

Diagnosis and repair of fuel injection, ignition, emissions control, and sensors.

Powertrain Control Module:

PCM diagnostics and repair.

Automatic Transmission:

Service and repair of the transmission assembly, torque converter, valve body, and solenoids.

Manual Transmission:

Service and repair of the transmission assembly, clutch, and related components.

Transfer Case:

Operation, diagnosis, and repair of 4WD systems.

Front Axle:

Front differential, CV joints, and axle shafts service.

Rear Axle:

Rear differential service and repair.

Suspension Front:

Struts, control arms, ball joints, wheel bearings, and alignment specifications.

Suspension Rear:

Shock absorbers, springs, control arms, and alignment specifications.

Steering System:

Power steering pump, rack and pinion, tie rods, and steering column service.

Brake System Front:

Disc brake pads, rotors, calipers, and hydraulic lines.

Brake System Rear:

Disc brake pads, rotors, calipers, and hydraulic lines (or drum brake service where applicable).

Anti Lock Braking System:

ABS sensor diagnosis, module repair, and hydraulic control unit service.

Wheels And Tires:

Tire pressure monitoring system, wheel torque specifications, and tire rotation.

Body Exterior:

Panel replacement, door mechanisms, bumpers, and exterior trim.

Body Interior:

Seat removal, dashboard disassembly, interior trim panels, and headliner service.

HVAC System:

Compressor, condenser, evaporator, blower motor, refrigerant recharge, and climate control module.

Lighting System:

Headlights, taillights, interior lights, and bulb replacement procedures.

Instrument Panel:

Gauges, warning lights, and cluster repair.

Audio System:

Radio, speakers, and amplifier service.

Power Windows Locks:

Motor and switch replacement for power windows and door locks.

Wiper Washer System:

Wiper motors, linkage, and washer pump service.

Safety Restraints:

Airbag system diagnosis and replacement procedures (crucial safety information).

Cruise Control:

System diagnosis and repair.

Remote Keyless Entry:

System operation and potential troubleshooting.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules and procedures for oil changes, filter replacements, and fluid checks.

Engine Overhaul:

Comprehensive step-by-step instructions for engine rebuilding.

Transmission Rebuild:

Complete overhaul procedures for both automatic and manual transmissions.

Brake Replacement:

Front and rear brake pad and rotor replacement, caliper service.

Suspension Repair:

Replacement of struts, shocks, control arms, ball joints, and tie rods.

Electrical Troubleshooting:

Systematic diagnostic approaches for electrical faults using wiring diagrams.

Diagnostic Trouble Codes:

List of DTCs and their probable causes and corrective actions.

Fluid Flush And Fill:

Procedures for flushing and refilling all vehicle fluids.

Component Replacement:

Detailed instructions for replacing virtually all major and minor components.

Alignment Procedures:

Wheel alignment specifications and adjustments.

HVAC Service:

Refrigerant handling, component replacement, and leak detection.

Body Panel Repair:

Instructions for removing and installing body panels and associated hardware.

Interior Component Removal:

Step-by-step guides for removing seats, dashboard, and trim pieces.

Technical Depth

Depth:

Comprehensive (covering from basic maintenance to complete overhaul and advanced diagnostics).

Diagnostic Tools Required:

Mentions of necessary diagnostic tools and equipment (e.g., scan tools, multimeters).

Torque Specifications:

Detailed torque specifications for all critical fasteners.

Clearances And Tolerances:

Specifications for critical component clearances and tolerances during assembly.

⚙️ Engine Specifications

Primary Engine

Engine Code:

2.4L (ED1) PowerTech I4

Displacement:

2429 cc

Bore X Stroke:

90.0 mm x 94.0 mm

Compression Ratio:

9.1:1

Horsepower Bhp:

150 bhp @ 5,800 rpm

Torque Lb Ft:

165 lb-ft @ 4,000 rpm

Engine Configuration:

Inline 4-cylinder

Valvetrain:

SOHC (Single Overhead Camshaft) with 16 valves

Fuel Induction:

Multi-port Fuel Injection (MPI)

Cooling System:

Pressurized liquid cooling system

Optional Engine

Engine Code:

3.7L (EER) PowerTech V6

Displacement:

3701 cc

Horsepower Bhp:

205 bhp @ 5,200 rpm

Torque Lb Ft:

235 lb-ft @ 3,800 rpm

Engine Configuration:

V-type 6-cylinder (90 degree V-angle)

Valvetrain:

SOHC (Single Overhead Camshaft) with 12 valves (3 valves per cylinder)

Fuel Induction:

Multi-port Fuel Injection (MPI)

Performance

Emission Control:

Federal Tier 1, OBD-II compliant

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

70.4 L (18.6 US gal)

🔧 Transmission

Standard

Type:

4-speed automatic (42RLE)

Optional

Type:

5-speed manual (NV1500)

Features

Transfer Case Standard:

Command-Trac NV242 (Part-time, 2-speed with 2WD, 4WD Part-Time, 4WD Full-Time, Neutral)

Transfer Case Optional:

Selec-Trac NV242 (Full-time, 2-speed with 2WD, 4WD Full-Time, Neutral)

Axle Ratio Standard:

3.73:1

Axle Ratio Optional:

4.10:1 (with larger tires)

📐 Dimensions

Exterior

Length:

4432 mm (174.5 in)

Width:

1806 mm (71.1 in)

Height:

1656 mm (65.2 in) (2WD), 1674 mm (65.9 in) (4WD)

Wheelbase:

2690 mm (106.0 in)

Ground Clearance:

213 mm (8.4 in)

Interior

Passenger Volume:

2630 L (92.9 cu ft)

Cargo

Cargo Volume Behind Rear Seats:

845 L (29.8 cu ft)

Cargo Volume Max:

1929 L (68.1 cu ft)

Weights

Curb Weight Min:

1650 kg (3638 lb)

Curb Weight Max:

1770 kg (3902 lb)

Gross Vehicle Weight Rating:

2250 kg (4960 lb)

Towing Capacity:

Up to 2000 kg (4400 lb) with V6 and factory tow package

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

Good (for 2004 model year testing, where applicable)

NHTSA Frontal Passenger:

Good (for 2004 model year testing, where applicable)

IIHS Moderate Overlap Frontal:

Acceptable (for 2004 model year testing, where applicable)

Active Features

Standard (Anti-lock Braking System)

Traction Control:

Optional

Electronic Stability Control:

Optional (ESP - Electronic Stability Program)

Passive Features

Airbags Front:

Standard (Driver and front passenger airbags)

Airbags Side:

Optional (Front side airbags)

Seatbelts:

Three-point seatbelts with pretensioners for all seating positions.

💡 Technology Features

Infotainment

Audio System:

Base AM/FM stereo with CD player, optional premium audio systems, optional SiriusXM Satellite Radio.

Display:

Center console display for radio and climate controls.

Driver Assistance

Cruise Control:

Standard on most trims.

Power Mirrors:

Standard, heated optional.

Connectivity

Auxiliary Input:

Optional (typically 1/8" jack on higher trims).

Power Outlets:

12V auxiliary power outlets.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 10,000-12,000 km (6,000-7,500 miles) or 6 months, whichever comes first (using synthetic oil).

Oil Filter Replacement:

With every oil change.

Engine Air Filter:

Every 40,000-50,000 km (25,000-30,000 miles).

Cabin Air Filter:

Every 20,000-25,000 km (12,000-15,000 miles).

Spark Plugs:

I4: 160,000 km (100,000 miles) (if using long-life plugs like iridium). V6: 100,000 km (60,000 miles).

Coolant Flush:

Every 5 years or 100,000 km (60,000 miles).

Automatic Transmission Fluid Change:

Every 60,000-80,000 km (35,000-50,000 miles).

Manual Transmission Fluid Change:

Every 80,000-100,000 km (50,000-60,000 miles).

Transfer Case Fluid Change:

Every 80,000-100,000 km (50,000-60,000 miles).

Brake Fluid Flush:

Every 2 years or 40,000 km (25,000 miles).

Drive Belt Replacement:

Inspect every 40,000 km (25,000 miles), replace as needed (typically 100,000-160,000 km service interval).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 synthetic (preferred for cooler climates and optimal protection) or SAE 10W-30.

Engine Oil Capacity I4:

4.4 L (4.7 US qt)

Engine Oil Capacity V6:

5.2 L (5.5 US qt)

Coolant Type:

Mopar OAT (Organic Additive Technology) coolant or equivalent HOAT (Hybrid Organic Additive Technology) coolant - typically orange or pink.

Automatic Transmission Fluid Type:

ATF+4 (Chrysler Material Standard MS-9602).

Manual Transmission Fluid Type:

Gear oil SAE 75W-90 GL-3 or GL-4.

Transfer Case Fluid Type:

ATF+4 (for NV242 models).

Power Steering Fluid Type:

Mopar Power Steering Fluid or equivalent Dexron III ATF.

Brake Fluid Type:

DOT 3.

Known Issues

Climate Control Actuators:

HVAC blend door actuators can fail, leading to improper air temperature or airflow direction.

Oil Leaks:

Valve cover gaskets and oil pan gaskets are known to leak over time.

Suspension Components:

Front suspension bushings, ball joints, and tie rod ends can wear out prematurely, especially with off-road use.

Radiator Leaks:

Plastic end tanks on radiators can crack and leak coolant.

Rear Main Seal:

Rear main crankshaft seal leaks can occur, particularly on higher mileage vehicles.

Fuel Pump Module:

The fuel pump module or sender unit can fail, causing erratic fuel gauge readings or no-start conditions.

Death Wobble:

While more associated with solid axle Jeeps, steering and suspension component wear can still lead to steering instability.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Jeep is renowned for its off-road prowess and durable, capable vehicles dating back to WWII.

Model Evolution

Cherokee Lineage:

The KJ Cherokee (2002-2007) replaced the XJ Cherokee and was the first Cherokee generation to feature unibody construction, following the Cherokee Sport platform.

Kj Generation Design:

Characterized by its distinctive 'four-eyed' front-end styling and more car-like crossover platform than its predecessors.

Production

Production Period:

2002-2007

Manufacturing Locations:

United States (Toledo, Ohio), Egypt, China, Venezuela.

🏆 Awards & Recognition

Recognitions

Off Road Capability Awards:

Often recognized by off-road publications for its capabilities within its class.

Design Awards:

While not a primary focus, its distinctive styling received comment.