🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Year:

2002

Platform Code:

TJ

👋 Introduction

Market Segment:

Compact/Mid-size SUV, known for off-road capability and iconic design.

Key Competitors:

Toyota Tacoma, Ford Bronco (previous generation), Suzuki Samurai (previous generation), Land Rover Defender (previous generation).

Vehicle Attributes:

Removable doors and roof, solid front and rear axles (on many models/configurations), iconic Jeep styling, robust off-road prowess, versatile functionality.

📋 Manual Details

Coverage Areas:

Introduction, Lubrication & Maintenance, Suspension, Differential & Driveline, Brakes, Clutch, Cooling, Audio/Video, Chime/Buzzer, Electronic Control Modules, Engine Systems, Heated Systems, Horn, Ignition Control, Instrument Cluster, Lamps, Power System, Restraints, Speed Control, Vehicle Theft Security, Wipers/Washers, Wiring, Engine, Exhaust System, Frame & Bumpers, Fuel System, Steering, Transmission and Transfer Case, Tires/Wheels, Body, Heating & Air Conditioning, Emissions Control

Manual Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

Operating Systems:

All Versions of Windows & Mac

Printability:

All pages are printable

Delivery Method:

Instant Download

Software Requirements:

Adobe PDF Reader, WinZip

📖 Manual Coverage

Systems Covered:

Engine (including engine systems, cooling, fuel, ignition, exhaust), Drivetrain (transmission, transfer case, differentials, driveline components), Suspension, Steering, Brakes, Chassis, Electrical System (wiring, lighting, power system, instrument cluster, audio/video, chimes, security, speed control, wipers/washers), HVAC, Body, Frame, Emissions Control, Restraints, Clutch.

Procedures Included:

Routine maintenance, troubleshooting, diagnostic procedures, repair and overhaul of all major vehicle systems and components, component replacement, adjustments, specifications for torque, clearances, fluid capacities, electrical schematics, and diagnostic trouble codes (DTCs).

Technical Depth:

Comprehensive diagnostic and repair information suitable for professional technicians and advanced DIY enthusiasts, covering everything from basic fluid changes to complete engine and transmission rebuilds.

Engine Repair:

Detailed step-by-step instructions for engine disassembly, inspection, repair, and reassembly of the 4.0L I6 and 2.4L I4 engines, including timing, valve adjustments, piston ring replacement, bearing service, and gasket replacement.

Transmission Rebuild:

Comprehensive guides for overhauling the NV3550 manual transmission and 42RLE automatic transmission, including clutch replacement, gear set inspection, seal replacement, and torque converter service.

Suspension And Steering:

Procedures for suspension component replacement (shocks, springs, control arms, track bars), steering gear repair/replacement, power steering pump service, and wheel alignment specifications.

Brake System Service:

Detailed instructions for brake pad and rotor replacement, brake caliper service, drum brake adjustment and replacement, master cylinder overhaul, bleeding the brake system, and ABS component diagnostics.

Electrical Diagnostics:

Extensive wiring diagrams for all vehicle systems, diagnostic flowcharts for electrical faults, troubleshooting procedures for the instrument cluster, lighting, power windows, door locks, and starter/charging systems.

Heating And Ac:

Service and repair procedures for the air conditioning system, heater core replacement, blower motor service, and HVAC control module diagnostics.

Body And Frame:

Repair procedures for the frame, body panels, bumpers, doors, and soft/hard top components. Includes instructions for rust repair and panel replacement.

Fuel And Exhaust:

Diagnosis and repair of the fuel system (fuel pump, injectors, fuel lines), exhaust system components (catalytic converter, mufflers, pipes), and emissions control systems.

Torque Specifications:

Specific torque values for virtually every fastener on the vehicle, essential for proper assembly and preventing damage.

Clearances And Tolerances:

Critical measurement specifications for engine components, transmission gears, suspension bushings, and other parts to ensure correct operation.

Diagnostic Trouble Codes:

Listing of common Diagnostic Trouble Codes (DTCs) and their potential causes and diagnostic steps.

Component Identification:

Diagrams and descriptions to help identify and locate all major components and sub-assemblies.

📊 Manual Specifications

File Format Details:

Digital PDF, allowing for text searchability and easy navigation. Quality is high resolution for clear viewing of diagrams and text.

Print Quality:

Printable to high quality, suitable for printing at home or a professional print shop.

Binding Type:

Not applicable (Digital Download)

Paper Type:

Not applicable (Digital Download)

⚙️ Engine Specifications

Engine Options:

2.4L 'PowerTech' I4 (less common for TJ), 4.0L 'High Output' I6 (most common and sought-after).

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Multi-point Fuel Injection (MPI)

40L Engine Code:

ERH (4.0L I6)

Engine Oil Capacity:

5.0 US quarts (4.7 L) with filter for 4.0L I6, 4.5 US quarts (4.3 L) with filter for 2.4L I4

Engine Oil Type:

API certified SAE 10W-30 or 10W-40 (check owner's manual for specific temperature ranges)

🔧 Transmission

Transmission Options:

5-speed manual (NV3550) or 4-speed automatic (42RLE)

Transfer Case Model:

NV241OR 'Atlas' (Rubicon models), NV231 (SE, Sport, X models)

Manual Transmission Features:

Synchromesh on all gears, robust construction for off-road use.

Automatic Transmission Fluid:

Mopar ATF+4 (MS-9602)

Manual Transmission Fluid:

GL-3 or GL-4 75W-90 synthetic gear oil (NV3550), NV231/NV241OR use Mopar Manual Transmission Lubricant (or equivalent)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm) for standard wheelbase, 103.4 inches (2626 mm) for the long wheelbase (LJ, introduced later but relevant for TJ platform)

Overall Length:

Approximately 150-160 inches depending on bumper and spare tire configuration.

Curb Weight:

Approx. 3,100 - 3,500 lbs (1406 - 1588 kg) depending on configuration.

Towing Capacity:

2,000 lbs (907 kg) typically.

🛡️ Safety Features

NHTSA Ratings:

Varies by year and specific test, generally moderate for its era. Rollover resistance was a concern for SUVs of this period.

Braking System:

Front ventilated discs, rear solid discs or drums depending on model and options. ABS available on some models.

Airbags:

Driver and passenger front airbags.

Seat Belts:

3-point front seat belts, 2-point rear lap belts in standard models, 3-point rear belts in later models or aftermarket configurations.

💡 Technology Features

Audio System:

Factory AM/FM/CD player with optional premium sound system. Basic speaker setup.

Traction Control:

Not typically available or standard on the 2002 model year TJ Wrangler.

Connectivity Features:

Limited to basic audio input (auxiliary input on some aftermarket head units). No Bluetooth or USB connectivity from the factory.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6 months, depending on driving conditions and oil type used (refer to manual for specifics).

Tire Rotation:

Every 5,000 to 7,500 miles (8,000 to 12,000 km)

Coolant Change:

Every 30,000 miles (48,000 km) or 2 years for original fill, check manual for replacement fluid type.

Coolant Type:

Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) 50/50 antifreeze/water mixture.

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent Dexron III/Mercon ATF.

Common Problems:

Actuator failures in the HVAC blend doors, occasional death wobble (shimmy) due to worn suspension/steering components, rust on body panels and frame, leaks from the soft top or hardtop seals, exhaust manifold cracks on the 4.0L I6.

Common Maintenance Tasks:

Checking and topping off fluids, inspecting U-joints, greasing suspension components (if applicable), inspecting brakes, checking tire pressure.

📚 Vehicle History

Jeep Legacy:

Continuation of the Jeep CJ (Civilian Jeep) lineage, maintaining its reputation for off-road capability and open-air driving experience.

Tj Introduction:

Introduced for the 1997 model year as a replacement for the YJ Wrangler, featuring coil springs instead of leaf springs for improved ride and handling.

Production Period:

1997-2006

Manufacturing Plants:

Toledo, Ohio, USA

🏆 Awards & Recognition

Off Road Awards:

Consistently ranked highly by off-road enthusiasts and publications for its capability and aftermarket support.