Jeep Wrangler 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Model Code: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Key Attributes: Iconic...

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UGS: 357563

Mots clés: 2002 Car Cars Jeep Misc Wrangler

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Model Code:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Key Attributes:

Iconic off-road capability, ruggedness, open-air driving experience, utilitarian design.

Competitive Analysis

Competitors 2002:

Toyota Tacoma (Off-Road Variants), Ford Explorer, Chevrolet Blazer, Nissan Xterra.

Key Features

Platform Advantage:

Solid front and rear axles, short wheelbase (for most trims), high ground clearance, robust drivetrain options.

Iconic Status:

Represents the quintessential Jeep experience, highly customizable for off-road use.

📋 Manual Details

Coverage Areas

Primary Coverage:

2002 Jeep Wrangler (TJ Platform)

Engine Coverage:

4.0L Inline-6 (AMC 242) and 2.4L Inline-4 (PowerTech)

Transmission Coverage:

NV3550 5-speed Manual, 42RLE 4-speed Automatic

Drivetrain Coverage:

Command-Trac NV241GII Transfer Case, Dana 30 (Front), Dana 35c (Rear) or Dana 44 (Rear - Optional)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Printed Manual

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, assembly, disassembly, tuning, lubrication, cooling system, fuel system, exhaust system, intake system.

Engine Electrical:

Ignition system, starting system, charging system, ECM/PCM diagnosis and repair, sensors, actuators.

Transmission Manual:

NV3550: Disassembly, assembly, clutch system, internal repairs, diagnostics.

Transmission Automatic:

42RLE: Disassembly, assembly, hydraulic control, torque converter, diagnostics.

Drivetrain Components:

Transfer case (NV241GII) service, front and rear axle (Dana 30, Dana 35c, Dana 44) overhaul, differential service, driveshaft and U-joint repair.

Suspension Steering:

Front and rear suspension systems (leaf spring and solid axle), steering gear, power steering system, wheel alignment specifications.

Brakes:

Front disc brakes, rear drum brakes (standard), optional rear disc brakes, ABS system diagnosis and repair, brake fluid specifications, bleeding procedures.

Electrical System:

Full wiring diagrams, lighting systems, power windows/locks, instrument cluster, body control modules, accessory circuits, diagnostic trouble codes (DTCs).

Body And Frame:

Frame inspection and repair, body panel removal and installation, interior trim, convertible top service, doors, hood, tailgate.

HVAC:

Heating, ventilation, and air conditioning system service, refrigerant handling, component diagnosis and replacement.

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel lines, evaporative emissions (EVAP) system.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, pipes, hangers.

Procedures Included

General Maintenance:

Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid change, tire rotation, belt inspection/replacement.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, wiring diagram interpretation.

Major Repairs:

Engine rebuilds, transmission overhauls, differential rebuilds, suspension component replacement, brake caliper/rotor replacement.

Electrical Diagnostics:

Testing sensors, actuators, relays, fuses, and wiring harnesses. Interpreting diagnostic trouble codes (DTCs).

Bodywork Repair:

Panel alignment, rust repair assessment, bumper replacement, door hinge adjustment, convertible top linkage repair.

Special Tools:

Identification and usage of specialized tools required for specific procedures.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and drivetrain rebuilds, including detailed electrical diagnostics and wiring schematics.

📊 Manual Specifications

File Format

Format:

Printed, physical document.

Print Quality

Quality:

Professional offset printing, clear diagrams and text.

Binding Type

Binding:

Typically perfect binding or comb binding for ease of use in a workshop environment.

Paper Type

Paper:

Durable, semi-gloss paper stock to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

AMC 242 (4.0L Inline-6)

Displacement 1:

3952 cc (242 cubic inches)

Configuration 1:

Inline 6-Cylinder, Overhead Valve (OHV)

Horsepower 1:

181 hp @ 4600 rpm

Torque 1:

222 lb-ft @ 3200 rpm

Optional Engine

Engine Code 2:

PowerTech (2.4L Inline-4)

Displacement 2:

2429 cc (148 cubic inches)

Configuration 2:

Inline 4-Cylinder, Single Overhead Cam (SOHC)

Horsepower 2:

150 hp @ 5200 rpm

Torque 2:

175 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 (Regular)

🔧 Transmission

Standard

Transmission Type 1:

New Venture Gear NV3550

Gears 1:

5-Speed Manual

Optional

Transmission Type 2:

Chrysler 42RLE

Gears 2:

4-Speed Automatic

Features

Transfer Case:

New Process NV241GII (Command-Trac 2-speed part-time 4WD)

Manual Fluid Spec:

Mopar Manual Transmission Lubricant (or equivalent MT-1 rated fluid)

Automatic Fluid Spec:

ATF+4 (MS-9602)

📐 Dimensions

Exterior

Wheelbase 2 Door:

93.4 inches (2372 mm)

Length 2 Door:

155.4 inches (3947 mm)

Width 2 Door:

66.5 inches (1689 mm)

Height 2 Door:

71.6 inches (1819 mm)

Ground Clearance:

approx. 10.2 inches (259 mm)

Cargo

Cargo Volume 2 Door:

25.1 cu ft (behind rear seat)

Weights

Curb Weight 2 Door 4.0L:

approx. 3350 lbs (1519 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver 2002:

Four stars (out of five)

NHTSA Frontal Passenger 2002:

Four stars (out of five)

Active Features

Standard Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and passenger front airbags.

Rollover Protection:

Reinforced windshield frame and sport bar for enhanced rollover protection.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional premium sound system.

Display:

Basic LCD display for radio information.

Driver Assistance

Cruise Control:

Optional

Connectivity

Connectivity Features:

Limited by era; typically no Bluetooth or USB ports standard. Auxiliary audio input possible on some later models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months (severe service) / Every 7,500 miles or 6 months (normal service, synthetic oil recommended).

Engine Coolant Interval:

Every 30,000 miles or 24 months (if using conventional coolant) / Every 100,000 miles or 10 years (if using HOAT/OAT coolant).

Transmission Fluid Interval Auto:

Every 30,000 miles or 24 months (ATF+4 recommended)

Transmission Fluid Interval Manual:

Every 60,000 miles or 48 months (Mopar Manual Transmission Lubricant)

Differential Fluid Interval:

Every 30,000 miles or 24 months

Fluid Specifications

Engine Oil Spec:

SAE 5W-30 (preferred for 4.0L), API Service Classification SN or later.

Coolant Spec:

Chrysler Long Life Antifreeze/Coolant (MS-9769) or equivalent HOAT/OAT.

Brake Fluid Spec:

DOT 3

Known Issues

Common Problems 1:

Cracking of the exhaust manifold (4.0L engine) due to heat cycles.

Common Problems 2:

Stripped oil filter housing threads (some later TJ models, less common on 2002 but possible).

Common Problems 3:

Leaking rear main seal on 4.0L engine.

Common Problems 4:

desgaste del muelle de ballesta (leaf spring wear) en suspensiones traseras (common on older, heavily used vehicles).

Common Problems 5:

Oil filter adapter housing leaks (can cause oil loss).

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Tracing roots back to WWII Willys MB, synonymous with off-road capability and freedom.

Model Evolution

Tj Generation Start:

Introduced for the 1997 model year, replacing the YJ Wrangler.

Tj Key Features Vs Yj:

Return to coil springs (front and rear), improved ride comfort, modern interior, introduction of the 4.0L inline-6 as the primary engine.

2002 Updates:

Minor updates, often including feature packaging changes and potentially minor powertrain refinements. The 42RLE automatic transmission became more prevalent.

Production

Production Plant:

Toledo South Assembly Plant, Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized by off-road publications and enthusiasts for its capability.

Ratings

Value Retention:

Known for strong resale value, particularly well-maintained or desirable trims.