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Jeep 2002 WJ User Manual

Jeep 2002 WJ
291 pages
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GROUP TAB LOCATOR
0a
Lubrication & Maintenance
7a
Cooling
8Ea
Electronic Control Modules
8Fa
Engine Systems
8Ia
Ignition Control
9a
Engine
11a
Exhaust System
14a
Fuel System
19a
Steering - 2.7L - Diesel
21a
Transmission and Transfer Case
25a
Emissions Control - 2.7L Diesel
Service Manual Comment Forms (Rear of Manual)

Table of Contents

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Jeep 2002 WJ Specifications

General IconGeneral
BrandJeep
Model2002 WJ
CategoryAutomobile
LanguageEnglish

Summary

LUBRICATION & MAINTENANCE

SPECIFICATIONS - FLUID CAPACITIES

Details fluid capacities for various vehicle components like fuel tank, engine oil, etc.

INTERNATIONAL SYMBOLS

Explains symbols used for lubricant and fluid inspection locations.

PARTS & LUBRICANT RECOMMENDATION

Covers recommendations for Mopar parts, lubricants, and chemicals for servicing.

FLUID TYPES

Discusses different types of fluids like engine coolant, engine oil, and their properties.

LIFT POINTS

Provides standard procedures for hoisting and jacking vehicle lifting points.

JUMP STARTING

Outlines standard procedures and safety precautions for jump starting a disabled vehicle.

EMERGENCY TOW HOOKS

Describes the purpose and usage of emergency tow hooks.

TOWING

Details towing recommendations, safety precautions, and procedures for different vehicle types.

COOLING - 2.7L DIESEL

OPERATION—COOLING SYSTEM

Explains how the cooling system regulates engine operating temperature and provides heat.

DIAGNOSIS AND TESTING

Covers methods for diagnosing and testing cooling system issues.

ENGINE COOLING SYSTEM OVERHEATING

Details common causes and driving techniques to avoid engine overheating.

RADIATOR CAP LEAKING STEAM AND /OR COOLANT INTO RESERVOIR BOTTLE

Discusses conditions related to radiator cap leaks and potential causes.

HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING

Describes issues where hoses collapse during engine cool-down.

NOISY FAN

Addresses causes and corrections for noisy fan conditions.

INADEQUATE AIR CONDITIONER PERFORMANCE

Discusses poor A/C performance related to the cooling system.

INADEQUATE HEATER PERFORMANCE

Covers issues with inadequate heater performance and gauge readings.

HEAT ODOR

Addresses causes of heat odor, such as damaged heat shields or fan drive issues.

ACCESSORY DRIVE

DRIVE BELTS

Covers visual diagnosis, noise diagnosis, and potential causes/corrections for drive belt issues.

BELT TENSIONERS

Describes the description and operation of automatic belt tensioners.

ENGINE

ENGINE - 2.7L DIESEL

Provides a general description of the 2.7L CDI diesel engine, including its specifications.

COOLANT

Explains the function, types, and properties of engine coolant, including safety warnings.

ENGINE COOLANT TEMP SENSOR

Details the removal and installation procedures for the engine coolant temperature sensor.

ENGINE COOLANT THERMOSTAT

Covers the removal and installation procedures for the engine coolant thermostat.

WATER PUMP

Details the removal and installation procedures for the water pump.

RADIATOR FAN

Describes the hydraulic radiator fan, its operation, and strategy.

RADIATOR PRESSURE CAP

Explains the description, operation, diagnosis, cleaning, and inspection of the radiator pressure cap.

RADIATOR

Describes the radiator construction and the cooling module assembly.

CYLINDER HEAD

Covers procedures for cylinder head bolt inspection, surface measurement, removal, and installation.

VALVE SPRINGS

Details the removal and installation procedures for valve springs.

CAMSHAFT(S)

Describes how to check camshaft position and remove/install camshafts.

ENGINE BLOCK

Covers standard procedures for replacing engine core and oil gallery plugs.

CRANKSHAFT

Details procedures for measuring journals, assigning bearing shells, and removing the crankshaft.

FLYWHEEL

Covers the removal and installation procedures for the flywheel.

PISTON & CONNECTING ROD

Describes pistons and connecting rods, including checking and repairing connecting rods.

PISTON RINGS

Covers the standard procedure for fitting piston rings, including side clearance and gap measurement.

VIBRATION DAMPER

Covers removal and installation procedures for the vibration damper.

VACUUM PUMP

Describes the description, operation, removal, and installation of the vacuum pump.

OIL JET

Details the removal and installation of oil jets in the engine block.

OIL PAN

Covers removal and installation procedures for the oil pan.

OIL PUMP

Details the removal, installation, and chain procedures for the oil pump.

OIL COOLER & LINES

Covers removal and installation procedures for the oil cooler and its lines.

INTAKE MANIFOLD

Describes the intake manifold's inlet port shut off system and its operation.

TIMING CHAIN COVER

Details removal and installation procedures for the timing chain cover.

TIMING BELT/CHAIN AND SPROCKETS

Covers removal procedures for the bottom guide rail, intermediate gear, and timing chain.

ELECTRONIC CONTROL MODULES

ENGINE CONTROL MODULE

Provides description, operation, and removal/installation of the ECM.

TRANSMISSION CONTROL MODULE

Provides description, operation, and control functions of the TCM.

ENGINE SYSTEMS

CHARGING

Describes the charging system components for diesel engines, including generator and battery.

GENERATOR

Details the description, removal, and installation of the generator assembly.

GENERATOR DECOUPLER PULLEY

Explains the description and operation of the generator decoupler pulley.

DIAGNOSIS AND TESTING - GENERATOR DECOUPLER

Outlines diagnostic procedures and possible causes for generator decoupler failures.

STARTING

SPECIFICATIONS

Provides specifications for the diesel starter motor, including power rating and test parameters.

STARTER MOTOR

Covers the removal and installation procedures for the starter motor.

IGNITION CONTROL

GLOW PLUG

Describes the description, operation, removal, and installation of glow plugs for cold starting.

GLOW PLUG RELAY

Details the description, operation, and diagnosis of glow plug relays.

EXHAUST SYSTEM AND TURBOCHARGER - 2.7L DIESEL

DESCRIPTION - 2.7L DIESEL

Describes the diesel engine exhaust system components and alignment.

DIAGNOSIS AND TESTING - DIESEL ENGINE

Provides a chart for diagnosing exhaust system issues like noise and leaks.

TURBOCHARGER SYSTEM

Details the description and operation of the variable turbine turbocharger system.

WASTEGATE

Covers the removal and installation of the waste gate solenoid.

CHARGE AIR COOLER AND PLUMBING

Describes the charge air system, its operation, and diagnosis of leaks.

FUEL SYSTEM

FUEL INJECTION

Covers the camshaft and crankshaft position sensors, fuel pressure sensor, and fuel injectors.

FUEL DELIVERY

Covers bleeding air from the fuel system and fuel filter/water separator service.

FUEL PUMP

Covers the description, operation, removal, and installation of the high and low pressure fuel pumps.

FUEL LINES

Details the removal and installation of high pressure fuel lines.

STEERING - 2.7L - DIESEL

PUMP

Covers removal, installation, reservoir, pulley, and hoses for the power steering pump.

RESERVOIR

Details the removal and installation procedures for the power steering reservoir.

PULLEY

Covers removal and installation procedures for the power steering pump pulley.

HOSES

Details removal and installation procedures for various power steering hoses.

TRANSMISSION AND TRANSFER CASE

AUTOMATIC TRANSMISSION - W5J400

Describes the W5J400 automatic transmission, its gear ratios, and identification.

TRANSFER CASE - NV247

Covers removal, disassembly, inspection, assembly, and installation of the NV247 transfer case.

BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM

Explains the description, operation, and diagnosis of the BTSI system.

DRIVING CLUTCHES

Describes the front, middle, and rear multi-plate driving clutches (K1, K2, K3).

HOLDING CLUTCHES

Describes the front, middle, and rear multi-plate holding clutches (B1, B3, B2).

INPUT SPEED SENSORS

Details the description and operation of the input speed sensors (N2, N3).

OIL PUMP

Covers the description, operation, disassembly, and assembly of the oil pump.

PARK LOCK CABLE

Details the removal and installation procedures for the park lock cable.

PISTONS

Describes pistons, their operation, and pressure principles like Pascal's Law.

PLANETARY GEARTRAIN

Explains the description and operation of the three planetary gear sets.

SHIFT MECHANISM

Covers the description, operation, and adjustments for the gear shift mechanism.

EMISSIONS CONTROL - 2.7L DIESEL

DESCRIPTION

Explains the ECM's role in controlling fuel injection and engine systems, and DTCs.

FUEL PRESSURE

Details how the ECM uses a fuel pressure sensor to monitor fuel pressure issues.

Fuel Injector Malfunctions

Explains how the ECM detects electrical problems with fuel injectors.

ECM NON-MONITORED SYSTEMS

Lists systems and conditions not monitored by the ECM, for which DTCs are not displayed.

HIGH AND LOW LIMITS

Describes how the ECM compares input signals to programmed limits, triggering DTCs.

EXHAUST GAS RECIRCULATION

Describes the EGR system's function in reducing NOx emissions by recirculating exhaust gas.

VALVE

Details the description and operation of the EGR valve, including its removal and installation.

SOLENOID

Covers the description, removal, and installation of the EGR solenoid.

ON-BOARD DIAGNOSTICS

DESCRIPTION - DIAGNOSTIC TROUBLE CODES

Provides a list of DTCs for the 2.7L diesel engine and explains their meaning.

ACCESSING DIAGNOSTIC TROUBLE CODES

Explains how to display stored DTCs using the DRB III scan tool.

ERASING TROUBLE CODES

Describes the procedure for erasing DTCs after repairs using the DRB III scan tool.

ENGINE CONTROL MODULE (ECM) - DRBIII CODES

Lists generic scan tool codes and their corresponding DRB III scan tool display messages for ECM issues.

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