🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2002

Platform:

TJ

Chassis Code:

TJ

👋 Introduction

Segment:

Compact SUV, Off-Road Vehicle

Target Audience:

Off-road enthusiasts, Jeep owners seeking to perform maintenance and repairs themselves.

Competitors 2002:

Toyota Tacoma (in SUV variant), Suzuki Vitara, Ford Explorer (though larger).

Iconic Design:

Classic Jeep styling, removable doors and top.

Off Road Capability:

Renowned for its off-road prowess, typically featuring 4x4 systems like Command-Trac or optional Selec-Trac.

Cost Savings:

Inexpensive way to keep the vehicle working properly, avoiding dealership service costs.

Empowerment:

Empowers owners to understand and maintain their vehicle with official factory guidance.

📋 Manual Details

Coverage Scope:

Comprehensive factory workshop service and repair

Included Systems:

Engine mechanical, cooling, lubrication, fuel, exhaust, starting, charging, ignition, engine control, manual transmission, automatic transmission, transfer case, axles, suspension (front and rear), steering, brakes (front and rear), body, electrical, HVAC, interior trim, exterior trim, and supplemental restraint system.

Estimated Page Count:

Likely over 1500 pages (typical for a complete factory service manual)

Manual Type:

Factory Workshop Service Repair Manual

Language:

English

Format:

PDF

File Compatibility:

Win95/98/ME/XP/Vista/7/Linux/MAC

Delivery Method:

Instant Download

Shipping:

No Shipping Cost

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for cylinder head assembly, partial engine disassembly, engine mechanical overhaul, camshaft removal/installation, oil pump, water pump, and pulley compressor assembly.

Cooling System:

Engine coolant, cooling fan system, water pump, and radiator service.

Lubrication System:

Oil filter replacement, oil pump service, and general lubrication procedures.

Fuel System:

Fuel injectors, fuel lines, and related components.

Charging System:

Alternator, battery, and related wiring.

Starting System:

Starter motor and starter switch service.

Ignition System:

Spark plugs, ignition coils, and related ignition components.

Engine Control:

Engine Control System (ECU) diagnostics, sensors (camshaft position sensor), and wiring.

Transmission Manual:

Manual Transaxle Assy, Manual Transaxle System, manual transaxle oil, clutch master cylinder assy, clutch release cylinder assy, and clutch start switch assy.

Transmission Automatic:

Automatic Transaxle Assy, transmission valve body, and automatic transaxle fluid.

Drivetrain:

Front Differential Oil Seal, Rear Axle Beam, Rear Axle Hub, and associated components.

Suspension Front:

Front Suspension Arm, front shock absorber.

Suspension Rear:

Rear Suspension, Rear Coil Spring, rear shock absorber Assy.

Steering:

Power Steering Link Assy, steering sensor.

Brakes:

Brake actuator, rear brake system, brake fluid, parking brake lever, parking brake.

Body Exterior:

Rear Bumper, Back Door, Back Door Glass, Windshield Glass, Headlamp Assy, Headlamp Protector Retainer, Side Turn Signal Lamp Assy, Quarter Window Assy.

Body Interior:

Front Speaker Assy, Floor Shift Assy, Sun Roof System, Combination Meter.

HVAC:

Heater & Air Conditioner, Air Conditioner Refrigerant, Air Conditioning Blower Assy, Heater Or Boost Ventilator Control.

Electrical:

Wire Harness Repair, lighting system, power window control system, power door lock control system, headlamp dimmer switch assy, transmission wire.

Safety Srs:

Supplemental Restraint System (SRS), Air Bag Sensor Rear, Air Bag Sensor Front, Passenger Air Bag Assy, Curtain Shield Air Bag Assy, Center Air Bag Sensor Assy, Seat Position Air Bag Sensor.

Maintenance:

Routine maintenance, fluid changes, filter replacements, belt adjustments.

Troubleshooting:

Diagnostic procedures and symptom-based troubleshooting for various systems.

Repair:

Step-by-step repair procedures for most major components and systems.

Diagnostics:

Detailed diagnostic flowcharts and specifications for engine control, electrical, and other systems.

Removal Installation:

Procedures for removing and installing major assemblies like cylinder heads, transmissions, axles, and body panels.

Wiring Diagrams:

Implicitly included in the electrical section for wire harness repair and system diagnostics.

Depth:

Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.

Accuracy:

Authoritative and accurate, based on original manufacturer specifications.

📊 Manual Specifications

File Type:

PDF

Searchability:

Assumed searchable text within the PDF for efficient navigation.

Print Capability:

Printable pages for physical reference.

Binding:

N/A (Digital PDF)

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Inline 6-Cylinder

Engine Displacement:

4.0L (242 cubic inches)

Engine Code:

AMC 242

Horsepower Approx:

190 hp @ 4600 rpm

Torque Approx:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Cooling Capacity Approx:

11 quarts

Oil Capacity Approx:

6 quarts (with filter)

Recommended Oil Viscosity:

SAE 10W-30 (check manual for specific climate conditions)

🔧 Transmission

Transmission Type:

5-Speed Manual (NV3550)

Transmission Type:

4-Speed Automatic (42RLE)

Transfer Case:

Command-Trac NV241 GII (standard) or Selec-Trac NV241 HD (optional)

Manual Trans Fluid:

Refer to manual for specific specification (often API GL-3 or GL-4 75W-90 or 80W-90)

Automatic Trans Fluid:

ATF+4 (Chrysler Material Standard MS-9602)

Transfer Case Fluid:

NP241: Mopar Manual Transmission Lubricant (or equivalent 75W-90 GL-3/GL-4)

📐 Dimensions

Wheelbase:

93.4 inches

Length:

151.3 inches

Width:

66.5 inches

Height:

70.6 inches

Curb Weight Approx:

3,500 - 3,800 lbs (depending on configuration)

Towing Capacity Approx:

2,000 lbs

Gross Vehicle Weight Rating Approx:

4,500 - 4,800 lbs

🛡️ Safety Features

NHTSA Rollover Resistance:

Typically 4 out of 5 stars for 4WD models (specific to vehicle configuration)

Airbags:

Driver and Passenger front airbags (Supplemental Restraint System).

Seatbelts:

Three-point seat belts.

ABS:

Standard Anti-lock Braking System (ABS) on front and rear wheels.

Traction Control:

Not standard on most 2002 models; primarily an off-road focused vehicle.

💡 Technology Features

Audio System:

Factory AM/FM/CD or cassette player, with optional premium sound systems.

Connectivity:

Basic; no factory navigation or Bluetooth typically available for this model year.

Cruise Control:

Available option, typically on higher trim levels.

Keyless Entry:

Available option.

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 5,000 miles or 6 months (refer to manual for specific recommendation based on driving conditions).

Engine Air Filter:

Inspect every 7,500 miles, replace as needed or every 15,000-30,000 miles.

Spark Plugs:

Typically every 30,000 - 100,000 miles depending on plug type (e.g., copper vs. platinum/iridium). Refer to manual for exact spec.

Transmission Fluid Auto:

Inspect fluid level and condition regularly, change per severe service schedule or approximately every 30,000 - 60,000 miles.

Transmission Fluid Manual:

Check for leaks, fluid changes are typically less frequent, often at 60,000 - 100,000 miles.

Transfer Case Fluid:

Inspect for leaks, change at higher mileage intervals like 60,000 - 100,000 miles.

Coolant Flush:

Every 30,000 - 50,000 miles or 2-3 years.

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF+4 (refer to manual to confirm)

Common Problems:

Oil filter adapter housing leaks, rear main seal leaks (especially on higher mileage 4.0L engines), exhaust manifold cracks (4.0L), sway bar disconnect issues (Rubicon models), clutch pedal assembly wear, common for some AC system issues.

Wheel Bolt Pattern:

5x4.5 inches (5x114.3 mm)

Tire Size Standard:

P215/75R15 (Sport), LT225/75R16 (Xtreme Sport, Sahara, LTD)

📚 Vehicle History

Brand Legacy:

Jeep has a long and storied history dating back to World War II, renowned for its go-anywhere, do-anything capability.

Tj Generation:

The TJ Wrangler, introduced for the 1997 model year, marked a significant evolution from the YJ generation, returning to round headlights and introducing coil springs for a vastly improved ride and articulation.

Updates 2002:

For 2002, the Wrangler TJ received minor updates, maintaining its core appeal. The 4.0L inline-six remained the dominant engine.

Manufacturing Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Awards:

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

Safety Certifications:

Complies with Federal Motor Vehicle Safety Standards (FMVSS).