Jeep 2002 WJ Manuals

Manuals and User Guides for Jeep 2002 WJ. We have 1 Jeep 2002 WJ manual available for free PDF download: Service Manual

Jeep 2002 WJ Service Manual (291 pages)

LUBRICATION & MAINTENANCE

Brand: Jeep | Category: Automobile | Size: 5.34 MB

Lubrication & Maintenance

2
Accessory Drive

16
- Diagnosis and Testing - Accessory Drive Belt
  16
- Drive Belts
  
  18
  - Installation
    18
  - Removal
    18
- Belt Tensioners Description
  
  19
  - Operation
    19
Engine

20
- Coolant Description
  
  21
  - Diagnosis and Testing - Cooling System Leaks
    21
  - Standard Procedure Standard Procedure - Adding Additional Coolant
    22
    
    Standard Procedure - Draining Cooling System
    23
    
    Standard Procedure - Refilling Cooling System
    23
- Coolant Recovery Pressure Container Description
  
  23
  - Operation
    23
  - Removal
    24
  - Installation
    24
- Engine Coolant Temp Sensor Removal
  
  24
- Engine Coolant Thermostat Removal
  
  25
  - Installation
    25
- Water Pump Removal
  
  25
  - Installation
    26
- Radiator Fan Description
  
  26
  - Operation
    27
  - Removal
    28
  - Installation
    29
- Radiator Pressure Cap Description
  
  30
  - Cleaning
    31
  - Diagnosis and Testing - Radiator Pressure Cap
    31
  - Inspection
    31
  - Operation
    31
  - Lubrication &
    
    41
  - Maintenance
    
    41
    
    Diagnosis and Testing - Radiator Flow Test
    31
    
    Radiator Description
    31
    
    Cleaning
    32
    
    Removal
    32
    
    Installation
    33
    
    Procedure
    33
    
    Procedure
    35
    
    Procedure
    36
    
    Transfer Case
    39
    
    Procedure
    41
Engine Systems

42
- Charging
  43
  - Description
    43
  - Generator Description
    
    43
    
    Installation
    43
    
    Removal
    43
  - Generator Decoupler Pulley Description
    
    44
    
    Operation
    44
    
    Diagnosis and Testing - Generator Decoupler
    45
    
    Procedure
    45
    
    Removal
    45
    
    Installation
    47
    
    Starter Motor
    50
Engine

54
- Engine - 2.7L Diesel
  55
  - Description
    55
    
    Description - Engine Cover
    56
  - Standard Procedure
    56
    
    Inspecting
    56
    
    Standard Procedure - Checking Oil Pressure
    56
    
    Standard Procedure - Compression
    56
    
    Testing Engine
    56
  - Removal
    57
    
    Removal - 2.7L Diesel Engine
    57
    
    Removal - Engine Cover
    58
  - Installation
    58
    
    Installation - 2.7L Diesel Engine
    58
    
    Installation - Engine Cover
    59
  - Specifications - Torque Specifications
    60
  - Special Tools
    64
    
    Cylinder Head Standard Procedure Standard Procedure - Cylinder Head Bolt Inspection
    69
    
    Standard Procedure - Measure Cylinder Head Surface
    69
  - Removal
    70
    
    Cover
    70
    
    Removal - Cylinder Head
    70
    
    Removal - Cylinder Head Front
    70
    
    Removal - Cylinder Head Guide Rail
    71
  - Installation
    72
    
    Installation - Cylinder Head
    72
  - Installation - Cylinder Head Front
    73
    
    Cover
    73
    
    Installation - Cylinder Head Guide Rail
    73
  - Cylinder Head Cover(S) Removal
    
    74
    
    Installation
    74
  - Valve Springs
    
    74
    
    Removal
    74
    
    Removal - Valve Springs
    74
    
    Removal - Valves
    74
    
    Installation
    75
    
    Installation - Valve Springs
    75
    
    Installation - Valves
    75
  - Camshaft(S)
    
    76
    
    Standard Procedure - Checking Camshaft Position
    76
    
    Installation
    78
  - Engine Block Standard Procedure Standard Procedure - Replacing Engine Core and Oil Gallery Plugs
    
    79
    
    Standard Procedure - Measuring Cylinder Bores
    80
  - Crankshaft
    
    81
    
    Crankshaft and Block Journals
    81
    
    Installation
    81
    
    Removal
    81
    
    Standard Procedure - Measure
    81
  - Crankshaft Oil Seal - Rear Removal
    
    82
    
    Installation
    82
  - Crankshaft Oil Seal - Front Removal
    
    83
    
    Installation
    84
  - Flywheel Removal
    
    84
    
    Installation
    85
  - Piston & Connecting Rod Description
    
    85
    
    Standard Procedure
    85
    
    Standard Procedure - Checking and Repairing Connecting Rods
    85
    
    Removal
    87
    
    Standard Procedure - Measuring Piston Protrusion
    87
    
    Installation
    88
  - Piston Rings
    
    90
    
    Standard Procedure - Piston Ring Fitting
    90
  - Vibration Damper Removal
    
    92
    
    Installation
    92
  - Vacuum Pump Description
    
    92
    
    Installation
    93
    
    Installation - Oil Separator
    93
    
    Operation
    93
    
    Removal
    93
    
    Removal - Oil Separator
    93
  - Oil Pan Removal
    
    94
  - Oil Jet Description
    
    94
    
    Installation
    94
    
    Removal
    94
  - Oil Pump Removal Removal
    
    95
    
    Installation
    95
    
    Removal- Oil Pump Chain
    95
    
    Installation - Oil Pump Chain
    96
  - Oil Cooler & Lines
    
    98
    
    Installation - Oil Cooler
    98
    
    Removal - Oil Cooler
    98
  - Intake Manifold
    
    99
    
    Description - Inlet Port Shut off
    99
    
    Operation - Inlet Port Shut off
    99
  - Timing Chain Cover
    
    99
    
    Removal
    99
    
    Installation
    100
    
    Tensioning Rail
    100
    
    Installation - Timing Chain
    106
  - Timing Chain Tensioner
    
    110
    
    Installation
    110
    
    Removal
    110
Exhaust System and Turbocharger - 2.7L Diesel

112
- Turbocharger System
  113
  - Description
    113
  - Operation
    113
  - Removal - Turbocharger
    113
  - Exhaust System and Turbocharger - 2.7L Diesel
    
    114
  - Installation
    114
  - Wastegate
    
    114
    
    Removal - Waste Gate Solenoid
    114
  - Charge Air Cooler and Plumbing Description
    
    115
    
    Cleaning
    115
    
    Diagnosis and Testing - Charge Air Cooler System - Leaks
    115
    
    Installation
    115
    
    Operation
    115
    
    Removal - Charge Air Cooler
    115
    
    Inspection
    116
    
    Installation - Charge Air Cooler
    116
Fuel System

118
- Fuel Injection
  119
  - Camshaft Position Sensor
    
    119
    
    Description
    119
    
    Installation
    119
    
    Operation
    119
    
    Removal
    119
  - Crankshaft Position Sensor Description
    
    119
  - Fuel Pressure Sensor Description
    
    119
    
    Installation
    120
    
    Removal
    120
    
    Description
    121
    
    Fuel Injector
    121
    
    Operation
    121
    
    Removal
    122
    
    Standard Procedure - Cleaning Fuel Injectors
    122
    
    Installation
    123
  - Fuel Rail Description
    
    124
  - Fuel Injection
    
    124
    
    Installation
    125
    
    Operation
    125
  - Manifold Air Flow (Maf) Sensor Description
    
    125
    
    Removal
    125
  - Fuel Pressure Solenoid Description
    
    126
    
    Operation
    126
    
    Removal
    126
    
    Installation - Fuel Pressure Solenoid
    127
  - Boost Pressure Sensor Description
    
    127
    
    Diagnosis and Testing - Boost Pressure Sensor
    128
    
    Operation
    128
  - Intake Air Temperature Sensor Description
    
    128
Fuel Delivery

129
- Fuel Filter / Water Separator Description
  130
  - Description
    130
    
    Description - High Pressure Pump
    130
    
    Description - Low Pressure Pump
    130
    
    Operation - Low Pressure Pump
    131
    
    Removal - High Pressure Pump
    131
    
    Installation - High Pressure Pump
    132
    
    Removal - Low Pressure Pump
    132
    
    Installation - Low Pressure Pump
    133
  - Fuel Pump
    
    130
    
    Installation
    130
    
    Operation
    130
  - Fuel Lines
    
    133
    
    Removal - High Pressure Lines
    133
    
    Installation - High Pressure Lines
    134
Transmission and Transfer Case

142
- Automatic Transmission - W5J400 Description
  144
  - Operation
    145
Table of Contents

162
- 1 2/4-5 Shift Solenoid
  163
  - 17 - 1-2/4-5 Command Valve
    163
  - 2 2/4-5 Overlap Valve
    
    163
  - 4 2/4-5 Holding Pressure Shift Valve
    
    163
  - Driving Clutch K1
    163
  - Holding Clutch B1
    164
    
    Diagnosis and Testing
    165
    
    Diagnosis and Testing - Automatic
    165
    
    Diagnosis and Testing - Preliminary
    165
    
    Transmission
    165
    
    Diagnosis and Testing - Automatic Transmission
    166
    
    Diagnosis and Testing - Road Testing
    166
    
    Removal
    169
    
    Standard Procedure - Aluminum Thread Repair
    169
    
    Disassembly
    170
    
    Assembly
    175
    
    Installation
    180
    
    Specifications - W5J400 Automatic Transmission
    182
    
    Special Tools - W5J400 Automatic Transmission
    183
    
    Brake Transmission Shift Interlock
    185
    
    Description
    185
    
    Operation
    185
  - Diagnosis and Testing - Brake Transmission Shift Interlock
    
    185
    
    Adjustments - Brake Transmission Shift Interlock
    186
  - Driving Clutch K1
    
    188
    
    Operation
    189
    
    Description
    198
    
    Operation
    203
    
    Assembly
    211
    
    Description
    217
    
    Description
    226
    
    Operation
    226
    
    Description
    236
    
    Operation
    236
    
    Operation
    237
    
    Removal
    239
    
    Shift Mechanism
    245
    
    Specifications
    254
    
    Torque Converter
    254
  - Driving Clutches Description
    
    188
  - Transfer Case - Nv247
    
    259
    
    Transfer Case - Nv247
    278

Jeep Categories

Automobile Stroller Automobile Accessories Scooter Car Navigation system

More Jeep Manuals

Jeep 2002 WJ Manuals

Jeep 2002 WJ Service Manual (291 pages)

Table of Contents

Lubrication & Maintenance

International Symbols

Parts & Lubricant Recommendation

Fluid Types

Fluid Fill/Check Locations

Maintenance Schedules Description

Lift Points

Jump Starting

Emergency Tow Hooks

Towing

Accessory Drive

Drive Belts

Belt Tensioners Description

Engine

Coolant Description

Coolant Recovery Pressure Container Description

Engine Coolant Temp Sensor Removal

Engine Coolant Thermostat Removal

Water Pump Removal

Radiator Fan Description

Radiator Pressure Cap Description

Lubrication &

Maintenance

Engine Systems

Generator Description

Generator Decoupler Pulley Description

Engine

Cylinder Head Cover(S) Removal

Valve Springs

Camshaft(S)

Engine Block Standard Procedure Standard Procedure - Replacing Engine Core and Oil Gallery Plugs

Crankshaft

Crankshaft Oil Seal - Rear Removal

Crankshaft Oil Seal - Front Removal

Flywheel Removal

Piston & Connecting Rod Description

Piston Rings

Vibration Damper Removal

Vacuum Pump Description

Oil Pan Removal

Oil Jet Description

Oil Pump Removal Removal

Oil Cooler & Lines

Intake Manifold

Timing Chain Cover

Timing Chain Tensioner

Exhaust System and Turbocharger - 2.7L Diesel

Exhaust System and Turbocharger - 2.7L Diesel

Wastegate

Charge Air Cooler and Plumbing Description

Fuel System

Camshaft Position Sensor

Crankshaft Position Sensor Description

Fuel Pressure Sensor Description

Fuel Rail Description

Fuel Injection

Manifold Air Flow (Maf) Sensor Description

Fuel Pressure Solenoid Description

Boost Pressure Sensor Description

Intake Air Temperature Sensor Description

Fuel Delivery

Fuel Pump

Fuel Lines

Transmission and Transfer Case

Table of Contents

2 2/4-5 Overlap Valve

4 2/4-5 Holding Pressure Shift Valve

Diagnosis and Testing - Brake Transmission Shift Interlock

Driving Clutch K1

Driving Clutches Description

Transfer Case - Nv247

Related Products

Jeep Categories