🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Year:

2002

Chassis Code:

TJ

👋 Introduction

Vehicle Segment:

Compact Sport Utility Vehicle (SUV), known for its off-road capability.

Key Competitors:

While the Wrangler occupies a unique niche, competitors in the broader compact SUV market during this era included the Toyota RAV4, Honda CR-V, and Ford Escape. However, none offered the same level of dedicated off-road prowess.

Design Philosophy:

Iconic, rugged, open-air design with removable doors, roof, and windshield for an unparalleled connection to the outdoors. Body-on-frame construction for durability and off-road articulation.

Off Road Capability:

Renowned for its 4x4 systems (Command-Trac and optional NV241 Rock-Trac transfer case), solid axles, and high ground clearance.

Manual Value Proposition:

Provides the essential, factory-authorized information needed for accurate diagnosis, maintenance, and repair of the 2002 Jeep Wrangler. Crucial for preserving its legendary capabilities and ensuring longevity.

📋 Manual Details

Coverage Type:

Complete Factory Workshop Service Repair Manual

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

Delivery:

Instant Download

Shipping:

No Shipping Cost

📖 Manual Coverage

Engine Mechanical:

Detailed coverage including cylinder block assembly, cylinder head assembly, camshaft, crankshaft, pistons, connecting rods, valves, valve clearance adjustment, oil pump, and partial engine components.

Cooling System:

Comprehensive information on radiator assembly, water pump assembly, cooling fan system, engine coolant specifications, and thermostat.

Fuel System:

In-depth coverage of fuel tank, fuel pump, fuel injectors, throttle body assembly, and fuel system diagnostics.

Ignition System:

Details on spark plugs, ignition coils, and ignition system troubleshooting.

Emission Control Systems:

Information on emission control systems, including charcoal canister and diagnostics.

Exhaust System:

Coverage of exhaust pipes, mufflers, and exhaust system components.

Engine Control System:

Includes SFI System (Sequential Multi-port Fuel Injection), knock sensor, camshaft position sensor, and engine control module (ECM) related diagnostics.

Transmission Manual:

Detailed coverage of manual transaxle assembly, manual transaxle oil specifications, and manual transaxle system diagnostics.

Transmission Automatic:

Coverage of automatic transaxle assembly, torque converter clutch, and automatic transaxle fluid specifications.

Drivetrain Front Axle:

Information on front axle hub, front differential oil seal, and front drive shaft.

Drivetrain Rear Axle:

Includes rear axle beam, rear axle hub, differential case assembly, and rear drive shaft.

Suspension Front:

Detailed coverage of front suspension system, front stabilizer bar, front shock absorber, front suspension arm, and front wheel alignment.

Suspension Rear:

Comprehensive information on rear suspension system, rear coil spring, rear shock absorber assembly, and rear wheel alignment.

Steering System:

Covers steering system, power steering, power steering link assembly, steering column, and steering sensor.

Brake System:

In-depth coverage including brake master cylinder, brake booster, brake pedal, front brake, rear brake, brake actuator, brake fluid specifications, and parking brake system (parking brake cable, parking brake lever).

Wheel Tire System:

Information on wheel and tire system, tire & wheel specifications, and wheel bolt patterns.

Electrical Charging System:

Coverage of charging system, generator assembly, and battery maintenance.

Electrical Starting System:

Details on starter assembly and starting system diagnostics.

Electrical Lighting System:

Covers headlamp assembly, front marker lamp assembly, rear combination lamp assembly, center stop lamp assembly, side turn signal lamp assembly, and license plate lamp assembly.

Electrical Instrumentation:

Information on instrument panel, combination meter, and related sensors.

Electrical Audio Visual:

Coverage of radio receiver assembly, audio & visual system, front speaker assembly, rear speaker assembly, and amplifier antenna assembly.

Electrical Accessories:

Details on cigarette lighter assembly, horn, and horn button assembly.

Air Conditioning HVAC:

Comprehensive coverage of air conditioning system, heater radiator assembly, air conditioning blower assembly, air conditioning amplifier assembly, heater & air conditioner controls, receiver condenser assembly, and air conditioning refrigerant.

Wiper Washer System:

Details on wiper and washer system, wiper rubber, windshield wiper motor assembly, rear wiper motor assembly, and washer nozzle.

Safety Srs Airbag:

Extensive coverage of supplemental restraint system (SRS), including front seat airbag assembly, side airbag sensor assembly, rear air bag sensor, center air bag sensor assembly, passenger air bag assembly, curtain shield air bag assembly, seat position air bag sensor, and spiral cable sub-assembly (for airbag clock spring).

Safety Seatbelts:

Covers seat belt systems including front seat belt, rear seat belt, and seat belt warning system.

Body Exterior:

Includes front bumper, rear bumper, fender panel mudguard, side mudguard, hood, back door garnish, back door, rear door, front door, rear door glass weatherstrip, front door glass weatherstrip, roof drip side finish moulding, roof headlining, windshield glass, quarter window assembly, and outer rear view mirror assembly.

Body Interior:

Covers instrument panel, steering column, seat, and center cluster module switch.

Body Repair:

Includes sections dedicated to body repair procedures.

Electrical Wiring:

Contains comprehensive wiring diagrams for electrical system troubleshooting and repair.

Electrical Power Control:

Details on power window control system, power door lock control system, and shift lock system.

Electrical Sensors:

Covers various sensors including skid control sensor, yaw rate sensor, speed sensor front, transmission revolution sensor, and more.

Maintenance:

Routine maintenance procedures, fluid checks and changes, filter replacements, and general upkeep.

Troubleshooting:

Diagnostic procedures for identifying and resolving common and complex vehicle issues across all systems.

Repair Overhaul:

Step-by-step instructions for component removal, installation, and overhaul for virtually every part of the vehicle.

Component Testing:

Detailed testing procedures for electrical components, sensors, actuators, and mechanical parts.

Specifications:

Torque specifications, fluid capacities, electrical resistance values, and other critical technical data.

Wiring Diagrams:

Extensive and detailed wiring diagrams for all electrical circuits, facilitating diagnosis and repair.

Safety Systems:

Procedures for servicing and diagnosing airbag systems, seatbelts, and related safety components.

Depth:

Comprehensive factory-level detail suitable for professional technicians and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format:

PDF

Printability:

Printable pages

Searchability:

Searchable text for quick information retrieval

Compatibility:

Win/Mac

Estimated Page Count:

1000+ pages (typical for a complete factory service manual of this era and scope)

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

4.0L Inline-6 (e.g., AMC 242)

Displacement:

3957 cc (242 cubic inches)

Bore X Stroke:

98.4 mm x 86.6 mm (3.875 in x 3.41 in)

Compression Ratio:

8.8:1

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Oil Type Capacity:

API SG or SH, SAE 10W-30; 5.6 quarts (5.3 liters) with filter change.

Spark Plug Type:

Champion Copper Plus RC12LYC or equivalent

Common Issues:

Head gasket leaks (though less common on the 4.0L than previous generations), oil filter adapter housing leaks, distributor housing cracks, and occasional fuel pump issues.

🔧 Transmission

Transmission Type:

NV3550 5-speed Manual Transmission

Transmission Type:

42RLE 4-speed Automatic Transmission

Fluid Type:

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

Fluid Type:

ATF+4 (Automatic Transmission Fluid)

Transfer Case:

NV231 (Command-Trac) with optional NV241-OR (Rock-Trac)

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

154.4 inches (3922 mm)

Width:

66.7 inches (1694 mm)

Height:

70.2 inches (1783 mm)

Curb Weight Manual:

Approx. 3,428 lbs (1,555 kg)

Curb Weight Automatic:

Approx. 3,466 lbs (1,572 kg)

Towing Capacity:

2,000 lbs (907 kg)

Gvw:

4,400 lbs (1,996 kg)

🛡️ Safety Features

NHTSA Rollover Rating:

4 out of 5 stars (for models equipped with specific safety features)

Airbags:

Driver and front passenger airbags (optional side airbags for some models)

Seatbelts:

3-point front seat belts, rear lap belts (depending on configuration)

ABS:

Anti-lock Braking System (ABS) available, typically 4-wheel.

Traction Control:

Not standard on most models.

💡 Technology Features

Audio System:

Basic AM/FM radio with cassette player or optional CD player. Speaker configurations varied by trim level.

Display:

No integrated infotainment screen; primary information displayed via analog gauges and basic dashboard indicators.

Driver Assistance Features:

Minimal in comparison to modern vehicles. ABS was an option, but features like stability control, adaptive cruise control, or lane departure warning were not available.

Connectivity Options:

No Bluetooth or USB connectivity. Optional power windows and locks introduced in this era.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for specific conditions).

Tire Rotation Interval:

Every 5,000-7,500 miles.

Transmission Fluid Change:

Manual: Check condition every 30,000 miles; Automatic: Typically every 30,000-60,000 miles, depending on usage (refer to manual).

Cooling System Flush:

Every 30,000 miles or 2 years.

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent ATF+4

Transfer Case Fluid:

Mopar NV231/NV241 Transfer Case Lubricant (or equivalent SAE 75W-90)

Common Wear Items:

Control arm bushings, sway bar links, track bar bushings, universal joints (U-joints) on driveshafts, and clutch wear (on manual transmissions).

Common Electrical Issues:

Corrosion on grounds and battery terminals, failure of the windshield wiper switch, and intermittent issues with the fuel pump relay.

📚 Vehicle History

Jeep Legacy:

Jeep's lineage traces back to World War II Willys MB, establishing a global reputation for ruggedness and off-road capability.

Wrangler Tj Generation:

The TJ generation (1997-2006) marked a significant shift from the YJ with the reintroduction of round headlights and a coil-spring suspension for improved ride comfort and articulation, a departure from the YJ's leaf springs.

Manufacturing Plant:

Toledo, Ohio, USA

Production Years For Tj:

1997-2006

🏆 Awards & Recognition

Off Road Accolades:

Consistently lauded by off-road enthusiasts and publications for its segment-leading capability and aftermarket support.