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Jeep Cherokee KJ 2002-2007 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Generation Codes: KJ Production Years: 2002-2007 Codes Chassis Code: KJ 👋 Introduction Market Position Segment: Compact SUV / Crossover Target Audience: Off-road...
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Jeep Cherokee KJ 2002-2007 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Generation Codes:
KJ
Production Years:
2002-2007
Codes
Chassis Code:
KJ
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Target Audience:
Off-road enthusiasts, families, individuals seeking a versatile and capable compact SUV.
Competitive Analysis
Key Competitors:
Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra, Chevrolet Blazer.
Key Features
Distinctive Attributes:
Jeep's legendary off-road capability in a more compact and road-friendly package, available Selec-Trac NV242 transfer case, distinctive styling.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily North America, European variants may have minor differences)
Page Count
Total Pages:
2145
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, engine control systems (ECU), manual transmission, automatic transmission, transfer case, driveline, axles, CV joints.
Chassis:
Suspension (front and rear), steering system, braking system (ABS, parking brake), wheels and tires.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, body control module (BCM), power windows, power locks, mirrors, wipers, horn, audio system, climate control electronics, airbags, anti-theft system, diagnostic trouble codes (DTCs).
Body:
Exterior body panels, interior trim, seats, glass, doors, hood, tailgate, bumpers, paint and corrosion protection.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication points, tire rotation.
Diagnostics:
Troubleshooting procedures for all major systems, diagnostic trouble code (DTC) interpretation and resolution, electrical circuit testing, component testing.
Repair:
Step-by-step repair instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major systems.
Overhaul:
Detailed procedures for engine and transmission overhaul, including specifications for tolerances and clearances.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically, depending on PDF creation)
Print Quality
Resolution:
High resolution for clear text and diagrams
Scalability:
Scalable for printing individual pages or sections
Binding Type
Binding:
Not applicable (digital PDF)
Paper Type
Paper Type:
Not applicable (digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
2.4L PowerTech (ED4/EDZ)
Displacement:
2429 cc
Configuration:
Inline 4-cylinder, DOHC, 16 valves
Horsepower:
150 hp @ 5200 rpm (approx.)
Torque:
165 lb-ft @ 4000 rpm (approx.)
Secondary Engine
Engine Code:
3.7L PowerTech (EWG)
Displacement:
3701 cc
Configuration:
V6, SOHC, 12 valves
Horsepower:
205 hp @ 5200 rpm (approx.)
Torque:
235 lb-ft @ 4000 rpm (approx.)
Fuel System
Induction:
Electronic Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Performance
Emissions Control:
Catalytic converter, OBD-II compliant
🔧 Transmission
Standard
Transmission Type 2.4L:
5-Speed Manual Transmission (NSG 370)
Optional
Transmission Type 3.7L:
4-Speed Automatic Transmission (42RLE)
Features
Transfer Case Options:
Command-Trac (NV132 - part-time 2-speed), Selec-Trac (NV242 - full-time 2-speed).
Fluid Specifications
Automatic Transmission Fluid:
Chrysler ATF+4 (MS-9602)
Manual Transmission Fluid:
API GL-4, SAE 75W-90
Transfer Case Fluid:
Mopar Transfer Case Lubricant or equivalent (check manual for specific type)
📐 Dimensions
Exterior
Wheelbase:
104.1 inches (2644 mm)
Length:
173.5 inches (4407 mm)
Width:
71.0 inches (1803 mm)
Height:
67.6 inches (1717 mm)
Ground Clearance:
Approx. 8.1 inches (206 mm)
Weights
Curb Weight Min:
3600 lbs (1633 kg) (approx.)
Gross Vehicle Weight Rating Gvwr:
4750 lbs (2155 kg) (approx.)
Towing Capacity:
Up to 2000 lbs (907 kg) (check specific configuration and trailer brakes)
Cargo
Cargo Volume Behind Rear Seat:
30.5 cu ft (0.86 m³) (approx.)
Cargo Volume With Rear Seat Folded:
68.9 cu ft (1.95 m³) (approx.)
🛡️ Safety Features
Ratings
NHTSA Front Rollover Rating:
4 out of 5 stars (for most configurations)
IIHS Side Impact Rating:
Acceptable (for models equipped with side airbags, if applicable)
Active Features
Antilock Braking System ABS:
Standard on most models
Traction Control:
Available on some models
Electronic Stability Control Esc:
Not typically standard on this generation.
Passive Features
Airbags:
Frontal airbags for driver and front passenger, available side curtain airbags (check specific vehicle).
Seat Belts:
3-point seat belts with pretensioners in front, 3-point seat belts in rear.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional Infinity premium audio system.
Navigation:
Not commonly available in this generation; aftermarket options existed.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used. Consult manual for specifics.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection.
Spark Plug Replacement 2.4L:
Platinum: 60,000-100,000 miles (96,000-160,000 km). Iridium: 100,000+ miles (160,000+ km).
Spark Plug Replacement 3.7L:
Platinum: 60,000-100,000 miles (96,000-160,000 km). Iridium: 100,000+ miles (160,000+ km).
Coolant Flush Interval:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-4 years.
Fluid Specifications
Engine Oil Type 2.4L:
SAE 5W-30, API SM or higher, ILSAC GF-4 or higher.
Engine Oil Type 3.7L:
SAE 5W-30, API SM or higher, ILSAC GF-4 or higher.
Engine Oil Capacity 2.4L:
4.5 US quarts (4.3 liters) with filter
Engine Oil Capacity 3.7L:
5.0 US quarts (4.7 liters) with filter
Coolant Type:
OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) Mopar Antifreeze/Coolant (MS-9769 or equivalent)
Known Issues
Common Problems:
Front suspension components (ball joints, control arm bushings), rear differential leaks, power steering pump leaks, minor electrical gremlins (window motors, door locks), exhaust manifold cracks (on 3.7L), radiator issues.
Typical Repairs:
Replacement of worn suspension components, seal replacement, possible exhaust manifold repair/replacement.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Over 80 years of off-road vehicle development, known for durability and capability.
Model Evolution
Kj Generation Introduction:
The KJ Cherokee, introduced for the 2002 model year, represented a significant redesign from the previous XJ Cherokee, adopting a unibody construction and a more modern, rounded aesthetic.
Design Philosophy:
Designed to offer Jeep's signature capability in a smaller, more car-like platform, blending on-road comfort with off-road prowess.
Production
Manufacturing Location:
Toledo, Ohio, USA.
🏆 Awards & Recognition
Recognitions
Off Road Acclaim:
Generally well-regarded for its off-road capability within its class, often cited for its solid axle feel (though this is a unibody SUV).
Ratings
Consumer Reports Ratings:
Varied over the years, with some years receiving average to below-average reliability ratings, particularly for early models. This manual helps address potential reliability concerns.
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