Cherokee KJ 2002 ( Service Manual ENG ), JEEP
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JEEP
®
2002
LIBERTY
SERVICE MANUAL and
2.4L GAS SUPPLEMENT
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF DAIMLERCHRYSLER CORPORATION.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
Litho in U.S.A. Copyright © 2001 DaimlerChrysler Corporation
7.5M0901
FOREWORD
This manual is designed as a supplement to be used along with the 2002 Liberty service manual,
81-370-02060. It includes information related to the 2.4L gas engine installed in this vehicle by
DaimlerChrysler Corporation. For diagnosis or service procedures relating to other components or systems,
refer to the 2002 Liberty Service Manual.
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
GROUP TAB LOCATOR
Introduction
0
Lubrication & Maintenance
2
Suspension
2S
Suspension
3
Differential & Driveline
5
Brakes
5S
Brakes
6
Clutch
7
Cooling
7S
Cooling
8A
Audio
8B
Chime/Buzzer
8E
Electronic Control Modules
8F
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8J
Instrument Cluster
8L
Lamps
8LS
Lamps
8M
Message Systems
8N
Power Systems
8O
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8W
Wiring
9
Engine
9S
Engine
11
Exhaust System
11S
Exhaust System
13
Frame & Bumpers
14
Fuel System
19
Steering
21
Transmission and Transfer Case
22
Tires/Wheels
23
Body
24
Heating & Air Conditioning
25
Emissions Control
Component and System Index
2.4L Gas Component and System Index
Service Manual Comment Forms
NOTE: For New Vehicle Preparation information, see the separate
publication, 81-170-00003.
NOTE: Group names with the suffix
S
(
indicate groups pertaining to the
the 2.4L Gas Supplement
(
KJ
INTRODUCTION 1
INTRODUCTION
TABLE OF CONTENTS
page
page
FASTENER IDENTIFICATION
DESCRIPTION ..........................1
FASTENER USAGE
DESCRIPTION
DESCRIPTION ........................4
DESCRIPTION ........................4
THREADED HOLE REPAIR
DESCRIPTION ..........................4
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................4
METRIC SYSTEM
DESCRIPTION ..........................5
TORQUE REFERENCES
DESCRIPTION ..........................7
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
DESCRIPTION ..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................8
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION ..........................9
FASTENER IDENTIFICATION
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 1) and (Fig. 2).
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
2
INTRODUCTION
KJ
FASTENER IDENTIFICATION (Continued)
Fig. 1 FASTENER IDENTIFICATION
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