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Jeep LIBERTY KJ Full Service & Repair Manual 2003-2004

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🏷️ Basic Information Identification Make: Jeep Model: Liberty Generation Code: KJ Model Years Covered: 2003-2004 👋 Introduction Market Position Vehicle Segment: Compact SUV, known for its rugged styling and off-road...
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Jeep LIBERTY KJ Full Service & Repair Manual 2003-2004
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Liberty
Generation Code:
KJ
Model Years Covered:
2003-2004
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV, known for its rugged styling and off-road capability, positioned as a more affordable and accessible Jeep product.
Competitive Analysis
Key Competitors:
Ford Escape, Toyota RAV4, Honda CR-V, Nissan Xterra, Subaru Forester.
Key Features
Nj Kj Platform:
Built on the Chrysler Group's 'Compact' platform, shared with models like the Dodge Neon and PT Cruiser, but heavily modified for SUV application.
Design Philosophy:
Emphasized Jeep's distinctive styling cues with a boxy, utilitarian design, capable off-road features, and robust construction.
Target Audience
Buyer Profile:
Individuals seeking a capable, stylish SUV for everyday driving and light to moderate off-road adventures, with a focus on practicality and value.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
Digital Download (Computer, Tablet, Smartphone)
Licensing Model:
No Expiry Dates, No Extra Fees
Manual Specifications
File Format:
Likely PDF, optimized for digital devices.
Print Quality:
Designed for clear digital display, likely printable at home or professionally.
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, disassembly, assembly, component testing, timing procedures, lubrication system, cooling system, fuel delivery, exhaust system.
Engine Management:
Ignition system, emissions control, fuel injection system (MPI), diagnostic trouble codes (DTCs), sensor testing, ECU operation, component locations.
Transmission Manual:
Disassembly, assembly, inspection, repair of manual gearbox, clutch system, shifter mechanism, driveline components.
Transmission Automatic:
Overhaul, adjustment, troubleshooting of automatic transmission, valve body operation, torque converter, transmission control module (TCM), fluid and filter service.
Drivetrain 4Wd:
Transfer case operation and repair, front and rear axle assemblies, differentials, CV joints, propeller shafts, wheel hubs.
Braking System:
Front and rear disc brake systems, ABS system operation and diagnostics, brake fluid flush and bleeding procedures, parking brake system, component replacement (pads, rotors, calipers).
Suspension Steering:
Front and rear suspension components (struts, shocks, control arms, ball joints, sway bars), steering system (rack and pinion, power steering pump, steering column), wheel alignment specifications.
Electrical System:
Wiring diagrams for all vehicle systems, battery, charging system (alternator), starting system (starter motor), lighting system (headlamps, taillamps, interior lights), accessory circuits.
Body And Chassis:
Body panel removal and installation, door mechanisms, glass replacement, interior trim components, underbody components, frame repair (if applicable), corrosion prevention.
HVAC System:
Air conditioning system service, refrigerant charging, heating system operation, blower motor, climate control modules, cabin air filter replacement.
Safety Systems:
Airbag system operation and diagnostics, seat belt mechanisms, SRS module testing.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid replacement, tire rotation, lubrication points.
Diagnostic Troubleshooting:
Systematic diagnostic procedures for common and complex issues, using diagnostic trouble codes (DTCs), pinpoint tests, component testing methodologies.
Component Replacement:
Detailed step-by-step instructions for replacing major and minor components across all vehicle systems.
Rebuild Procedures:
Comprehensive instructions for complete engine, transmission, and differential rebuilds, including specifications and clearances.
Torque Specifications:
Precise torque values for all fasteners and critical engine, chassis, and suspension components.
Wiring Diagrams:
Detailed and clearly labeled electrical wiring diagrams for all vehicle systems, aiding in electrical troubleshooting and repair.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair and maintenance procedures.
Technical Depth
Depth Level:
Factory-level diagnostic and repair procedures.
Diagnostic Approach:
Comprehensive, systematic approach to diagnosing faults, including symptom analysis, DTC interpretation, and pinpoint tests.
Electrical Diagnostics:
Advanced electrical diagnostics, including circuit testing, voltage drop testing, continuity checks, and component resistance measurements.
Mechanical Diagnostics:
Detailed mechanical diagnostics for engine performance issues, drivability problems, suspension noises, and brake system faults.
⚙️ Engine Specifications
Primary Engine 2003 2004
Engine Code:
2.4L PowerTech (ED3)
Engine Type:
Inline 4-cylinder, DOHC, 16 valves
Displacement:
2351 cc (143.5 cubic inches)
Bore X Stroke:
87.5 mm x 98.0 mm (3.44 in x 3.86 in)
Compression Ratio:
9.4:1
Horsepower Net:
154 hp @ 5800 rpm (approx.)
Torque Net:
169 lb-ft @ 4000 rpm (approx.)
Fuel System:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline, 87 Octane (87 AKI) minimum recommended
Optional Engine 2003 2004
Engine Code:
3.7L PowerTech V6 (EER)
Engine Type:
V6, SOHC, 12 valves
Displacement:
3701 cc (225.8 cubic inches)
Bore X Stroke:
87.5 mm x 103.0 mm (3.44 in x 4.06 in)
Compression Ratio:
9.6:1
Horsepower Net:
210 hp @ 5200 rpm (approx.)
Torque Net:
235 lb-ft @ 4000 rpm (approx.)
Fuel System:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline, 87 Octane (87 AKI) minimum recommended
🔧 Transmission
Standard Transmission 2.4L
Type:
5-Speed Manual
Transfer Case:
NV134 (Command-Trac NV231 with low range)
Optional Transmission 2.4L And 3.7L
Type:
4-Speed Automatic (42RLE)
Transfer Case:
NV134 (Command-Trac NV231 with low range)
Features
Transmission Fluid Manual:
Mopar ATF+4 (MS-9602)
Transmission Fluid Automatic:
Mopar ATF+4 (MS-9602)
📐 Dimensions
Exterior Length
Value:
175.1 inches (4448 mm)
Exterior Width
Value:
72.3 inches (1836 mm)
Exterior Height
Value:
68.7 inches (1745 mm)
Wheelbase
Value:
104.2 inches (2647 mm)
Ground Clearance
Value:
8.1 inches (206 mm) (typical)
Curb Weight
Value 2.4L 4Wd:
3795 lbs (1721 kg) (approx.)
Value 3.7L 4Wd:
3940 lbs (1787 kg) (approx.)
Cargo Volume Behind Rear Seat
Value:
38.2 cubic feet (1081 liters)
Cargo Volume With Rear Seat Folded
Value:
63.0 cubic feet (1784 liters)
Towing Capacity
Value 2.4L:
2,000 lbs (907 kg)
Value 3.7L:
3,500 lbs (1588 kg)
🛡️ Safety Features
Ratings
NHTSA Front Driver:
5-Star (2003 model year)
NHTSA Front Passenger:
5-Star (2003 model year)
IIHS Front Offset Crash:
Good (2003 model year)
Active Features
ABS:
Standard (4-wheel anti-lock braking system)
Traction Control:
Optional on some trims, standard on higher trims.
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags
Seat Belts:
Three-point seat belts with pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Base systems typically featured AM/FM stereo with CD player. Premium Infinity sound systems were optional.
Display:
Basic LCD screen for radio display. No advanced touchscreen or navigation typically found in this generation.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Auxiliary Input:
Rarely standard on 2003-2004 models; may have been an aftermarket addition.
Bluetooth:
Not typically available from the factory for these model years.
🔧 Maintenance
Service Intervals Oil Engine
Interval Normal Use:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Interval Severe Use:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first.
Fluid Specifications Engine Oil
Type 2.4L:
SAE 5W-30, API Certified (Chrysler MS-6395)
Type 3.7L:
SAE 5W-30, API Certified (Chrysler MS-6395)
Fluid Specifications Coolant
Type:
Mopar Antifreeze/Coolant HOAT (5-Year/100,000 Mile Formula), or equivalent OAT/HOAT compatible coolant (e.g., Zerex G-05).
Fluid Specifications Brake Fluid
Type:
DOT 3 or DOT 4 brake fluid.
Fluid Specifications Power Steering Fluid
Type:
Mopar Power Steering Fluid or equivalent DEXRON III/MERCON ATF.
Known Issues Common
Topic 1:
Front Differential Failure: Premature wear or failure of the front differential, especially in 4WD models, often due to lubrication issues or manufacturing defects.
Topic 2:
Blend Door Actuator Failure (HVAC): The HVAC blend door actuators can fail, leading to incorrect air temperature or inability to switch between air vents.
Topic 3:
Sway Bar Links and Bushings: Wear and tear on sway bar links and bushings can lead to clunking noises over bumps.
Topic 4:
Radiator Issues: Premature leaks or clogging of the radiator can occur, impacting cooling performance.
Topic 5:
Power Steering Pump Leaks: Leaks from the power steering pump or hoses can lead to loss of assist and noisy steering.
Maintenance Schedule Key Items
Item 1 Interval:
Engine Oil & Filter: 7,500 miles / 6 months
Item 2 Interval:
Engine Air Filter: 15,000 miles / 12 months
Item 3 Interval:
Cabin Air Filter: 15,000 miles / 12 months
Item 4 Interval:
Spark Plugs (2.4L): 100,000 miles (or refer to manual for replacement intervals based on severe use).
Item 5 Interval:
Spark Plugs (3.7L V6): 100,000 miles (or refer to manual for replacement intervals based on severe use).
Item 6 Interval:
Brake Fluid Flush: Every 24 months, regardless of mileage.
Item 7 Interval:
Coolant Replacement: Every 5 years or 100,000 miles (first change), then every 3 years or 50,000 miles thereafter.
Item 8 Interval:
Automatic Transmission Fluid & Filter: Every 60,000 miles or as per severe service schedule.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long-standing reputation for producing rugged, go-anywhere vehicles, originating from its military roots in WWII.
Model Evolution
Kj Introduction:
The KJ Liberty replaced the Cherokee (XJ) in Jeep's lineup in North America, representing a shift to a unibody construction for improved ride comfort and packaging, while retaining Jeep's signature capability.
Kj Generation Timeline:
First generation (KJ) produced from 2002 to 2007. The 2003-2004 models represent the initial production years of this generation.
Production
Assembly Location:
Toledo, Ohio, USA.
Production Years Kj
Model Years:
2002-2007
🏆 Awards & Recognition
Recognitions
North American Truck Of The Year:
Jeep Liberty was named North American Truck of the Year for 2003.
Ratings
Kes Ratings:
Generally received favorable ratings for its off-road capability and value proposition, though interior quality and some powertrain aspects were noted as areas for improvement.
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