🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Year:

2002

Chassis Code:

TJ

Production Code:

TJ

👋 Introduction

Segment:

Compact/Mid-size Sport Utility Vehicle (SUV)

Target Audience:

Off-road enthusiasts, outdoor adventurers, utility buyers

Key Competitors:

Toyota Tacoma (early versions), Nissan Xterra, Ford Bronco (earlier generations), Suzuki Samurai/Vitara

Unique Selling Proposition:

Renowned off-road capability, solid front axle, classic open-air experience, robust platform

Design:

Iconic Jeep styling, removable doors and top, short wheelbase (typical for Wrangler)

Powertrain:

Proven inline-six engine, robust four-wheel-drive systems

Chassis:

Body-on-frame construction, solid front and rear axles

📋 Manual Details

Coverage Scope:

Complete Factory Service Repair

Included Sections:

Maintenance, Diagnostics, Repair, Overhaul, Wiring Diagrams, Specifications

Estimated Pages:

Approximately 2000+ (typical for full factory service manuals)

Type:

Factory Service Repair Manual (FSM)

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

4.0L Power Tech I-6 (TJ Engine Family), 2.5L (optional, less common for 2002 TJ)

Engine Management:

Ignition, Fuel Delivery, Emissions Control, Cooling System, Lubrication System

Transmission:

AX-15 Manual Transmission, NV3550 Manual Transmission, 30/42RLE Automatic Transmission

Drivetrain:

Transfer Case (NP231 Command-Trac), Front Axle (Dana 30), Rear Axle (Dana 35c C-clip, Dana 44 optional)

Suspension:

Front and Rear Multi-Link Solid Axle Suspension (Coil Springs, Shocks, Control Arms, Track Bars)

Steering:

Power Steering System, Steering Column, Steering Gear

Brakes:

Front Disc Brakes, Rear Drum Brakes (optional rear discs), Parking Brake System, ABS (if equipped)

Electrical:

Battery, Charging System, Starting System, Lighting, Instrumentation, Body Electrical, Powertrain Control Module (PCM) & Engine Control Module (ECM) related diagnostics

Body:

Body Panels, Doors, Hood, Fenders, Bumpers, Soft Top/Hardtop Components, Interior Trim

HVAC:

Heating, Ventilation, Air Conditioning System

Chassis:

Frame, Body Mounting, Fuel System (Tank, Lines, Pump), Exhaust System

Maintenance:

Fluid Changes (Oil, Coolant, Brake Fluid, Transmission Fluid, Axle Fluid), Filter Replacements, Inspections, Lubrication Points

Diagnostics:

Troubleshooting charts, Symptom-based diagnostics, Diagnostic Trouble Codes (DTCs), PCM/ECM data interpretation

Repair:

Component removal and installation, Rebuild procedures for major systems (engine, transmission, axles), Body panel repair, Electrical component repair

Installation:

Accessory installation guidance (often in separate supplements, but core systems covered)

Wiring Diagrams:

Comprehensive schematics for all electrical systems

Depth:

Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Tools:

References OBD-II scanner usage and interpretation of live data

Torque Specifications:

Detailed torque values for all fasteners and critical components

Clearances:

Specifications for critical component clearances and tolerances (e.g., ring gear backlash, piston-to-wall)

📊 Manual Specifications

Format:

PDF

Searchability:

Likely text-searchable if scanned properly

Quality:

High-resolution scans suitable for printing

Print Recommendation:

Printable in its entirety or by section

Binding:

N/A (Digital PDF Download)

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Code:

4.0L Inline-6 (G) - AMC/Chrysler 242 cu in

Engine Type:

Overhead Valve (OHV), Cast Iron Block, Aluminum Cylinder Head

Displacement:

3952 cc (242 cubic inches)

Horsepower:

190 hp @ 4,600 rpm

Torque:

235 lb-ft @ 3,200 rpm

Bore X Stroke:

3.88 in x 3.56 in (98.5 mm x 90.5 mm)

Compression Ratio:

8.8:1

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Ignition System:

Distributorless Ignition System (DIS) with Distributorless Coil Ignition (DCL) on later models, or distributor with coil pack.

Emissions Control:

Catalytic Converter, EGR Valve, Oxygen Sensors

🔧 Transmission

Transmission Type:

5-Speed Manual Transmission (NV3550)

Transmission Type:

4-Speed Automatic Transmission (30/42RLE)

Transfer Case:

NP231 Command-Trac (Part-Time 2-Speed Transfer Case)

Manual Transmission Fluid:

Mopar Manual Transmission Lubricant (MS-9224) or equivalent API GL-3/GL-4 SAE 75W-90

Automatic Transmission Fluid:

Mopar ATF+4 (MS-9602) or equivalent

Transfer Case Fluid:

Mopar NV241 Transfer Case Lubricant (MS-9050) or equivalent API GL-5 SAE 75W-90

📐 Dimensions

Wheelbase:

93.4 inches (2372 mm)

Length:

150.0 inches (3810 mm)

Width:

66.5 inches (1689 mm)

Height:

73.0 inches (1854 mm) (with soft top)

Ground Clearance:

Approx. 8.5 inches (216 mm)

Curb Weight:

Approx. 3400-3700 lbs (1542-1678 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4950 lbs (2245 kg)

Cargo Volume Behind Rear Seat:

Approx. 13.4 cubic feet (379 liters)

Cargo Volume With Rear Seat Folded:

Approx. 40.0 cubic feet (1133 liters)

🛡️ Safety Features

NHTSA Rollover Resistance:

3-star (for 2WD models, 4WD may vary slightly)

IIHS Crash Tests:

Adequate (for front impact in its era)

ABS:

Available (Optional on Rear Drum Brake models, standard on some trims/optional rear disc)

Traction Control:

Not typically available on this model year

Airbags:

Driver and Passenger Frontal Airbags

Seat Belts:

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

Rollover Protection:

Integral sport bar (roll cage) behind front seats

💡 Technology Features

Audio System:

Factory AM/FM/Cassette or AM/FM/CD player. Basic speaker setup.

Display:

Basic analog gauges and warning lights.

Cruise Control:

Available (Optional on some trims)

Keyless Entry:

Available (Optional)

🔧 Maintenance

Engine Oil Change:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first.

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed.

Spark Plugs:

Replace every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on plug type (e.g., copper, platinum, iridium).

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Transmission Fluid Change:

Manual: Inspect at 30,000 miles, replace as needed. Automatic: Every 60,000 miles (96,000 km) or 4 years.

Axle Fluid Change:

Every 30,000 miles (48,000 km), especially if used for off-roading.

Engine Oil Type:

SAE 10W-30 (preferred for 4.0L) or SAE 5W-30. Consult manual for specifics based on climate.

Engine Oil Capacity:

6 US quarts (5.7 liters) with filter

Coolant Type:

Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (50/50 mix with distilled water)

Brake Fluid Type:

DOT 3

Common Problems:

Cracked cylinder heads (especially early 4.0L), leaks (oil, coolant, transmission), sway bar disconnect issues (if equipped), transfer case chain stretch, rear main seal leaks, death wobble (requires diagnosis and proper alignment/component replacement).

Common Maintenance Items:

Regularly inspect and grease U-joints, control arm bushings, and ball joints.

📚 Vehicle History

Brand Legacy:

Jeep brand has a storied history dating back to World War II, known for rugged off-road vehicles.

Tj Introduction:

The TJ Wrangler generation was introduced for the 1997 model year, replacing the YJ.

Tj Distinctive Features:

Return to round headlights, introduction of coil spring suspension, new chassis and body design.

2002 Updates:

Minor interior refinements, potential for powertrain updates (check VIN specific).

Manufacturing Location:

Toledo North Complex, Toledo, Ohio, USA

Production Years:

1997-2006

🏆 Awards & Recognition

Off Road Awards:

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

Consumer Reports Ratings:

Varies by year and specific component; often praised for off-road, criticized for on-road comfort and reliability concerns related to known issues.

Emission Standards:

Meets U.S. EPA and California Air Resources Board (CARB) emission standards for the model year.