2002 Jeep Grand Cherokee problems

What is wrong

Chrysler (FCA US LLC) is recalling certain model year 2002-2003 Jeep Liberty vehicles manufactured January 9, 2001, to March 28, 2003, 2002-2004 Jeep Grand Cherokee vehicles manufactured February 13, 2001, to May 23 2003, and 2003-2004 Dodge Viper vehicles manufactured November 1, 2001, to June 30, 2004. Due to electrical noise beyond the tolerance of the air bag electronic control module (ECM), a component in the ECM may fail, causing the front air bags, side air bags, and/or seatbelt pretensioners to deploy inadvertently while the vehicle is being operated.

Risk

Inadvertent deployment of the air bags may increase the risk of injury and the possibility of a vehicle crash.

Remedy

Chrysler dealers will replace the air bag control module and side impact sensors as required, free of charge. This recall remedy was applied during earlier recall campaigns of these vehicles under safety recalls 12V527 and 13V040. All owners that have not had the recall repair performed under safety recalls 12V527 or 13V040 are strongly encouraged to have it performed and not wait for the final remedy to be deployed to the field. The recall began on December 29, 2015. Owners may contact Chrysler customer service at 1‑800‑853‑1403. Chrysler's number for this recall is R06.

Recall number 15V046000 · Recall details

What is wrong

Chrysler is recalling certain model year 2002 and 2003 Jeep Liberty vehicles manufactured January 9, 2001, through March 28, 2003, and 2002 through 2004 Jeep Grand Cherokee vehicles manufactured February 13, 2001, through May 23, 2003. A component in the air bag control module may fail causing the front airbags, side curtain airbags, and/or seatbelt pretensioners to deploy inadvertently while the vehicle is being operated.

Risk

Inadvertent deployment of the airbags may increase the risk of injury and the possibility of a vehicle crash.

Remedy

Chrysler will notify owners, and dealers will install a supplemental jumper harness to the airbag control module, free of charge. Owners were notified of the recall by interim letter in January 2013. The remedy for affected Liberty vehicles is expected to be available in April 2013. The remedy for affected Grand Cherokee vehicles is expected to be available later in the year. Owners may contact Chrysler at 1‑800‑247‑9753.

Recall number 12V527000 · Recall details

What is wrong

Chrysler is recalling 103,409 my 2001-2004 jeep grand cherokee vehicles with heated seats and with chrysler recall no. 06v‑197 completed (03-04 my) or seat heater elements service replacement (01-02 my). The front seat electric heater elements could overheat.

Risk

Overheating could potentially cause a fire or injury.

Remedy

Dealers will replace the front seat heater elements free of charge. The recall began on november 23, 2009. Owners may contact chrysler at 1‑800‑853‑1403.

Recall number 09V117000 · Recall details

What is wrong

On certain sport utility vehicles, the plastic blades of the electric motor driven cooling fan may separate and penetrate the shroud.

Risk

If this occurs while the hood is open, a person in the vicinity of the engine could be struck by the blade and injured.

Remedy

Dealers will replace the electric cooling fan modules free of charge. The recall began on september 4, 2006. Owners may contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 06V199000 · Recall details

What is wrong

On certain sport utility vehicles equipped with a 4.0l engine only, the design of the intake and exhaust manifolds could allow debris to accumulate at the #3 cylinder location.

Risk

This could result in a vehicle fire.

Remedy

Dealers will install a manifold shield to modify the air flow characteristics and to prevent the accumulation of debris in the area of the #3 cylinder. Owner notification began may 13, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 02V104000 · Recall details

What is wrong

On certain sport utility vehicles, the passenger air bag wiring harness was improperly manufactured.

Risk

This could cause improper air bag deployment in certain crash conditions.

Remedy

Dealers will add a wiring jumper to the existing circuitry to correct this condition. Owner notification began april 29, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 02V099000 · Recall details

What is wrong

Certain sport utility vehicles equipped with a fuel tank brush guard fail to comply with the requirements of fmvss no. 301, "fuel system integrity." the onboard refueling vapor recovery (orvr) control valve can become detached during a crash, allowing fuel leakage.

Risk

Fuel leakage in the presence of an ignition source can result in a fire.

Remedy

Dealers will either replace the fuel tank brush guard with a skid plate or reinforce the existing fuel tank brush guard with a reinforcement bracket. Owner notification will begin march 4, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 02V032000 · Recall details

What is wrong

Vehicle description: sport utility vehicles. The fuel inlet check valve could stick in the partially open position. This condition could cause fuel to spill out of the filler tube during refueling.

Risk

Fuel leakage in the presence of an ignition source could result in a fire.

Remedy

Dealers will inspect the fuel inlet check valve. Vehicles found to have a sticking fuel inlet check valve will have the fuel tank assembly replaced. Owner notification began december 24, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 01V374000 · Recall details

What is wrong

Vehicle description: sport utility vehicles. The onboard vapor recovery system vent hose may have been misrouted. This could allow water to enter the canister which can cause fuel to spill out of the filler tube when refueling the tank.

Risk

Fuel leakage in the presence of an ignition source could result in a fire.

Remedy

Dealers will inspect (and reposition as necessary) the vent hose. If the vent hose is found in the bent down position, and the vehicle has been driven more than 20 miles, the canister assembly will be replaced. Owner notification began december 3, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 01V348000 · Recall details

What is wrong

Vehicle description: certain sport utility vehicles are being recalled for a software error in the instrument cluster microprocessor. Under certain conditions, the cluster, with the majority of its gauges, illumination, and warning lamps, could become inoperative.

Risk

Driving the vehicle with an inoperative cluster could cause a distraction, increasing the risk of a crash.

Remedy

Dealers will re-flash the cluster software to correct the condition. Owner notification began october 8, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 01V288000 · Recall details

The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of inadvertent air bag deployments (IABD) occurring after the recall remedy for the federal safety agency recall 12V‑527 had been installed on recalled model year (MY ) 2002-2003 Jeep Liberty and MY 2002-2004 Jeep Grand Cherokee vehicles manufactured by Fiat Chrysler Automobiles (FCA).The recall was in response to the Office of Defects Investigation (ODI) investigation EA12-001 during which data provided by FCA indicate that the air bag circuitry inside the Occupant Restraint Control (ORC) module can degrade. ORC degradation can result in an inadvertent air bag deployment, without a crash or impact, while the vehicle is being operated.An IABD may involve frontal, side and belt pretensioner devices, and may result in injuries consisting of burns, cuts and bruises to the upper body region, and or the potential for a loss of control and or crash.The remedy FCA developed for 12V‑527 consisted of installing an in-line jumper harness with an integrated electrical filter for the circuits that connect to the air bag modules (squib circuits).This filter is intended to eliminate transient electrical spikes to the ORC which FCA asserted are responsible for the IABDs.ODI has identified a total of 9 the federal safety agency complaints across all affected vehicles indicating an IABD event occurring after the vehicle had previously been remedied under 12V‑527.In addition, FCA reported 12 additional complaints of post-remedy IABD events. The IABD events took place both while driving and while the vehicle was stationary. Six customers incurred injuries consistent with air bag deployments however no crashes were reported.As a response to this investigation, FCA has issued 2 new recalls involving the IABD.On January 27, 2015 FCA notified ODI that it would conduct a safety recall (15V‑046) to remedy potential IABD events occurring in 753,176 MY02-03 Jeep Liberty vehicles built through 03/28/03 and MY 2002-2004 Jeep Grand Cherokee vehicles built through 5/23/03.Note that this recall, which was scoped based on field IABD events does not include all MY 2003 Liberty or MY 2004 Grand Cherokee manufactured with the same level ORC module.According to FCA, the ORC degradation and subsequent electrical overstress condition that causes the air bags to deploy inadvertently is not fully remedied with the filter installed during the 12V‑527 campaign.To remedy IABDs under 15V‑046, FCA will install a new design ORC module using a next generation electrical architecture.The next generation architecture has been used in other non-subject vehicles for many years without evidence of IABD events occurring.In addition to this recall, on October 15, 2015 FCA advised the federal safety agency that it would conduct safety recall 15V‑673 to remedy potential IABD events in the remaining 284,089 MY 2003 Jeep Liberty and MY 2004 Jeep Grand Cherokee vehicles manufactured with the earlier generation ORC module that were not previously recalled.FCA initially did not recall these populations due to the lack of known IABD events.However, FCA is now aware of 7 IABD events occurring in this population. After consultation with ODI regarding the long term durability and noise toughness of the earlier ORC architecture, FCA decided to recall this population also.The recall actions initiated by the manufacturer address the safety risks identified by the investigation.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at http://www-odi.the federal safety agency.dot.gov/owners/SearchSafetyIssues under the following identification (ODI) numbers: 10622092, 10629705, 10619008, 10618842, 10626762, 106404

RQ14001

ODI has completed an extensive analysis of rear crash fuel tank system integrity data for the subject Jeep Cherokee, Grand Cherokee and Liberty vehicles (SVs).As of June 2013, ODI knew of 56 post-collision fatal fires, 28 non-fatal fires, and 6 fuel leak incidents (totaling 90 incidents, 75 fatalities and 58 injuries) involving the SVs.Based on this analysis, ODI issued a Recall Request Letter (RRL) on June 3, 2013 requesting that Chrysler recall the Grand Cherokee and Liberty vehicles due to the rate of fatal, non-fatal fire, and fuel leak incidents when compared to peer vehicles (compact and medium SUVs) built during the same time period.In the RRL, ODI described how the location of the aft-mounted fuel tank made the SVs vulnerable to rear impact crash fuel tank failures.During the analysis, besides the high speed/high severity crashes present in both the SV and peer vehicles, ODI observed a significant number of low and moderate speed rear impact crash related fires and leaks, particularly in the Liberty.The data also demonstrated that SVs originally equipped with towing hitch receivers (trailer hitches) appeared to be under-represented in rear-impact related fuel tank failures.In the RRL, ODI requested that Chrysler provide its response by June 18, 2013, otherwise the federal safety agency might proceed to an Initial Decision that the SVs contain a safety-related defect.Chrysler responded to the RRL on June 4, 2013 and vigorously disputed the tentative findings of the RRL.Among other things, Chrysler argued that the SVs had an overall safety record superior to their peers, met or exceeded all applicable federal motor vehicle safety standards (FMVSS) and only experienced fires in severe high energy rear impacts.Nonetheless, while continuing to maintain that the SVs did not contain a safety-related defect, Chrysler proposed a recall (13V‑252) of approximately 2.5M (1.6M currently registered) model year (MY) 1993 - 1998 Grand Cherokee (ZJ) and MY 2002-2007 Liberty (KJ) vehicles on June 18, 2013.The recall remedy submitted by Chrysler would employ a hitch receiver assembly consisting of a steel cross-member behind the fuel tank with forward-projecting arms bolted to the frame rails on either side of the fuel tank.For the MY 1999 - 2004 Grand Cherokee, Chrysler indicated it would conduct a customer satisfaction campaign and inspect vehicles equipped with aftermarket tow hitch receivers, and if necessary, replace any such hitch receivers whose conditionmay increase the risk of fuel system failure in rear crashes.Examination of the available data established that the MY 1999 - 2004 Grand Cherokee did not pose the same magnitude of safety risk as the MY 1993 - 1998 Grand Cherokee and MY 2002-2007 Liberty, particularly in low and moderate speed rear impacts.Because the agency has concluded that the vehicles do not present an unreasonable risk to safety, ODI is closing its investigation of the MY 1999 - 2004 Grand Cherokee.Although it was not within the scope of the Petition initiating this investigation or the Preliminary Evaluation preceding this EA, ODI also examined the performance of the MY 1993 - 2001 Cherokee as part of this investigation.the federal safety agency's assessment of the available data for the Cherokee did not establish an unreasonable risk in comparison to peer vehicles.ODI does not approve proposed defect remedies.While offering to install hitch receiver assemblies on the MY 1993-1998 Grand Cherokees and 2002-2007 Liberty, Chrysler did not, in ODI's view, provide enough evidence demonstrating the effectiveness of the proposed remedy in rear impacts.The Complete Summary for this Closing Resume (EA12-005) can be seen by

EA12005

the federal safety agency has conducted extensive analysis of the data regarding fuel tank integrity for the model year (MY) 1993-2004 Jeep Grand Cherokee (JGC). As a result of that work, the agency has decided to upgrade its safety defect investigation to an Engineering Analysis and to expand the scope of vehicles included in the investigation. the federal safety agency's assessment of the data collected during this investigation indicates that rear-impact-related tank failures and vehicle fires are more prevalent in the JGC than in the non-Jeep peer vehicles. In addition, the agency's analysis of its FARS data for the peer vehicles and three Jeep models shows a higher incidence of rear-impact, fatal fire crashes for the Jeep products.PE10-031 had focused on the fuel tank system integrity of the JGC vehicles during rear-end collisions and impacts.The fuel tank is located at the rear of the vehicle, between the bumper and axle, and is manufactured from a plastic material (HDPE).Three peer vehicles (across the same MY range as the JGC) were identified for comparative assessment: the Chevrolet Blazer, Ford Explorer, and Toyota 4Runner.ODI has collected and assessed a significant volume of data for the JGC and three peer vehicles under the Defect Petition (DP) 09-005 and PE10-031, much of which was either provided by the petitioner or by the subject and peer manufacturers in response to ODI's information request letters.the federal safety agency has also utilized its FARS database.Fatal crash data was collected for the JGC and its three peers, along with data for two other Jeep vehicles, the Cherokee and Liberty, which were also manufactured with rear mounted fuel tanks and assessed by ODI as Jeep peer vehicles.Based on the agency's current analysis, ODI is upgrading its investigation to determine whether the subject vehicles contain a defect that presents an unreasonable risk to safety.The subject vehicles for EA12-005 will be MY 1993-2004 JGC, MY 1993-2001 Cherokee, and MY 2002-2007 Liberty; the estimated production volumes for these vehicles is approximately 5.1 million, although attrition is a factor for the older vehicles.Please note that the counts shown in the above failure report summary are for the JGC only (values shown in the total column are unique).Data for the other Jeep models and possibly other peer models will be collected during the investigation.The ODI reports cited above can be reviewed online at www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification (ODI) numbers:506249, 549376, 734783, 869217, 10009553, 10335943, 10351589, 10351980, 10357528.

PE10031

In a letter dated October 2, 2009, the Center for Auto Safety (CAS) petitioned the federal safety agency to open a defect investigation and recall model year 1993-2004 Jeep Grand Cherokees.CAS alleged that the subject vehicles have defective fuel tank storage systems that present a fire hazard in crashes. CAS alleged that the plastic fuel tank's placement behind the rear axle and below the rear bumper, and the lack of adequate shielding, make it more vulnerable to rupture or leakage from a rear-impact by another vehicle (including damage from other components located on the Grand Cherokee), or in the case of rollover crashes, from other external objects.CAS also alleged that the fuel filler neck tears off in crashes.In its petition, CAS cites data from the federal safety agency's Fatality Analysis Reporting System (FARS) showing 172 fatal fire crashes with 254 fatalities involving the subject vehicles from calendar years 1992 through 2008.CAS stated that there have been at least 44 crashes with 64 total fatalities (subject and non-subject vehicles) where fire was entered as the Most Harmful Event (MHE) in the FARS database.In response to the CAS petition, ODI made a preliminary examination of available data.FARS data showed 2,988 occupants of the subject vehicles have died in crashes since 1992.Of those, 55 died in 44 crashes where fire was listed as the Most Harmful Event.Identifying crashes most likely associated with the alleged defect as described by CAS (defined as the subject vehicle being struck at the 5, 6 or 7 o'clock positions) isolated 10 crashes with 13 occupant fatalities.ODI also reviewed the Vehicle Owner Questionnaires (VOQ) database and identified 12 reports alleging A) a post-crash fuel tank leak and/or B) a post-crash fire potentially related to a fuel tank leak.Of the 12 reports, 10 involved fires (two involved fuel leaks only) with 9 alleged injuries and 1 alleged fatality.The existence of these post-crash fires does not, by itself, establish a defect trend.Further review and investigation into these incidents is needed to determine the existence of any relationship between the alleged defect and each fire or leak.It should be noted that ODI also conducted a preliminary review of the Early Warning Reporting (EWR) data that did not find the subject vehicles to be over-represented for post-crash fires.ODI's initial review neither supports nor excludes the possibility that a defect exists in the subject vehicles.However, ODI has always taken the position that vehicle fires pose a significant safety risk.Accordingly, ODI has granted the petition to further investigate the conditions associated with post-crash fires in these vehicles.

DP09005

Daimlerchrysler corporation (dcc) has notified the agency that it will conduct a safety recall (06v199) of certain jeep grand cherokee vehicles to replace the engine's electric motor driven cooling fan. The 182,875 vehicles included in the recall are model year (my) 2002 equipped with 4.0 liter (six cylinder) engines manufactured from february 4, 2002 through june 17, 2002; and my 2000 equipped with either the 4.0 liter (six cylinder) or the 4.7 liter (eight cylinder) engine manufactured from january 31, 2000 through june 12, 2000.dcc noted that their analysis of failed parts showed evidence of brittle fracture of the fan blade.dcc further stated, poor bonding between the resin material and the glass fibers was observed, which may be attributed to the injection molding process. Since the root cause of fan failure could not be conclusively identified dcc decided the recall scope would be determined by the build date range of the complaint vehicles.there were 48 reports for my 2000, and 196 for my 2002.odi will continue to monitor this issue for reports on vehicles outside of the recall scope.

EA05020

This investigation was opened on july 13, 2005, based on four odi consumer reports.odi contacted all of those complainants and each of them reported that pieces of the broken fan blade had damaged the radiator and penetrated through the protective fan shroud.since opening the investigation, odi has received 12 new consumer reports.in its response to odi's preliminary evaluation information request daimlerchrysler corporation provided additional owner reports and warranty data.this preliminary evaluation has been upgraded to engineering analysis ea05-020 to further study the issues regarding the alleged fan failures.

PE05039

Daimlerchrysler has recalled the zj models to incorporate a secondary detent spring into the shifter.even though the wj 6 cyl. Vehicles use the same manual detent lever that as the vehicles in the recall population, odi believes that the wj redesigned shifter, which improves floor shifter functionality and ergonomics, helps to provide feedback to the driver to indicate whether ?park? Has or has not been achieved.although the investigator was able to induce a ?false park? In the wj platform for 6 cyl. Vehicles, the level of difficulty was greater than that required for all zj models, and the complaint rate was significantly lower than the recalled zj population.further, the odi investigator was also able to create a ?false park? In peer vehicles with the same level of difficulty and frequency as the subject vehicle wj platform.the wj complaint rate was inflated due to national exposure through the press. The complaint rate prier to the july 5, 2001 media coverage for the wj vehicles is similar to the peer vehicle incident rate.based on the above, a safety-related defect trend has not been identified at this time in the wj population.accordingly, this investigation is closed with a safety recal for the zj platform only.

EA01017