2002 Jeep Grand Cherokee WJ 2.7L Diesel Engine Service Manual Supplement (P/N 81-370-02064)

This PDF manual set combines the 2002 Jeep Grand Cherokee WJ factory service manual with the 2002 WG 2.7L diesel service supplement, then adds four 2003 diagnostic-procedure volumes. DaimlerChrysler prepared the service information for professional automotive technicians, and the scan-tool routines, internal engine and transmission work, and special-tool requirements assume normal shop equipment and DRB III access.

• Powertrain and chassis coverage: 4.0L, 4.7L, and 4.7L High Output gasoline engines, the 2.7L common-rail diesel, 42RE, 545RFE, and W5J400 transmissions, NV242LD/HD and NV247 transfer cases, plus 186FBI, 198RBI, and 226RBA axles with Trac-Lok and Vari-Lok configurations.
• Engine repair material covers compression and oil-pressure diagnosis, engine removal and installation, cylinder-head and valve service, crankshaft and piston inspection, timing-system repair, lubrication work, and final adjustment. The diesel supplement adds common-rail fuel-system service, glow-plug diagnosis, turbocharger and wastegate work, charge-air-cooler leak testing, and fuel-system bleeding.
• Transmission sections take the 42RE, 545RFE, and W5J400 beyond routine maintenance with pressure testing, removal, internal disassembly, clutch and oil-pump inspection, reassembly, adjustment, and operational checks. Transfer-case chapters provide comparable repair depth for the NV242LD/HD and NV247.
• Axle and driveline chapters include propeller-shaft vibration diagnosis, single- and double-Cardan joint repair, axle-shaft and seal replacement, differential teardown, ring-and-pinion setup, bearing preload work, and final pattern checks. Vari-Lok service limits are identified where the differential is replaced as an assembly.
• Chassis repair extends beyond the axles to front and rear suspension, wheel alignment, steering gear and pump service, base-brake and parking-brake work, Teves Mark 20e ABS and adjustable-pedal diagnosis, cooling-system testing, and hydraulic-fan repair.
• Body diagnostics cover WJ/WG left- and right-hand-drive systems, including airbags, PCI-bus communication, HVAC, lighting, instrument cluster, EVIC, memory seats, power locks and windows, and tire-pressure monitoring.
• Programming and fault isolation include PCM and SKIM procedures, W5J400 TCM Quick Learn, ABS initialization, EVIC tire-pressure-sensor training, DTC-based tests, component locations, connector pinouts, wiring schematics, and post-repair verification. Supporting references include torque tables, fluid capacities, pressure-test data, wear limits, adjustment specifications, and electrical test values.

Repair depth and service tools

The 2002 WG supplement is meant to be used with the base WJ manual. Together they provide the mechanical repair procedures for the 4.0L, 4.7L, and 2.7L engine families and their related drivetrains rather than treating the diesel as an axle-only add-on. Diesel service-tool listings identify items such as Camshaft Locking Pin 8929, Timing Chain Retainer 8931, Crankshaft Lock 8932, Injector Remover 8938, and Chain Separator Tool 8948. W5J400 transmission work calls out Multi-use Spring Compressor 8900 and Pressing Tool 8901.

The axle procedures address the risk of trying to reduce pinion preload by backing off the nut; an over-crushed collapsible spacer can damage the spacer or bearings and requires replacement. On the W5J400, converter-to-driveplate bolts that are too long can damage the clutch surface inside the torque converter. High-pressure diesel fuel, hot pressurized coolant, brake hydraulics, airbag deployment circuits, and heavy drivetrain assemblies require the manual's isolation, pressure-release, and lifting precautions.

Diagnostic and diagram coverage

Representative factory drawings include the Jeep WJ/WG 4.0L Powertrain System, Jeep WJ/WG 4.7L Powertrain System, 45RFE/545RFE Transmission (WJ), Teves Mark 20e Controller Antilock Brake—ABS, and ECM Communication—Diesel schematics, along with W5J400 First through Fifth Gear Powerflow views. Hydraulic circuits, exploded assembly views, connector locations, splice details, and test charts support repair and fault tracing across the covered systems.

The full mechanical removal, overhaul, and repair coverage comes from the 2002 WJ base manual and 2002 WG diesel supplement. The 2003 material consists of dedicated Powertrain, Body, Chassis, and Transmission diagnostic volumes, not a complete 2003 mechanical service manual. Its Powertrain volume covers 4.0L and 4.7L gasoline systems, while its Transmission volume is specific to the 45RFE/545RFE. For the 2.7L diesel, the set provides the 2002 supplement's DTC references and service information rather than a full 2003 diesel fault-isolation volume.

PDF contents and publication numbers

The 3,972-page PDF set is broken down as follows:

• 2002 Grand Cherokee Service Manual, Publication No. 81-370-02064: 2,201 pages (2-page front matter plus 2,199-page body)
• 2002 WG 2.7L Diesel Service Manual Supplement, Publication No. 81-526-02088: 293 pages (2-page front matter plus 291-page body)
• 2003 Powertrain Diagnostic Procedures: 380 pages
• 2003 Body Diagnostic Procedures: 748 pages
• 2003 Chassis Diagnostic Procedures: 74 pages
• 2003 Transmission Diagnostic Procedures: 270 pages
• Separate 2003 service-supplement front matter: 6 pages