Jeep Wrangler TJ 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Year: 2002 Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Target Audience: Off-road enthusiasts,...

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Type: Car

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Sku: 391800

Tags: 2002 Car Cars Jeep Misc Wrangler TJ

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Off-road enthusiasts, Jeep owners seeking to perform their own maintenance and repairs, restoration projects.

Competitive Analysis

Key Competitors 2002:

Toyota Tacoma (off-road variant), Nissan Xterra, Ford Explorer Sport Trac.

Key Features

Vehicle Philosophy:

Iconic off-road capability, rugged design, and utilitarian functionality.

Manual Value Proposition:

Empowers owners with the knowledge to maintain and repair their TJ Wrangler, saving on labor costs and ensuring proper upkeep for peak performance.

📋 Manual Details

Coverage Areas

Coverage Scope:

Full Service and Repair

Page Count

Estimated Page Count:

1500-2000

Manual Type

Type:

Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Comprehensive coverage of 4.0L Inline-6 (242 ci) and 2.5L Inline-4 (150 ci) engines, including disassembly, inspection, assembly, and torque specifications.

Fuel System:

Fuel injection system (MPI), fuel pump, injectors, fuel filter replacement, fuel tank service, evaporative emission control (EVAP) system.

Ignition System:

Ignition coil testing, spark plug replacement, distributorless ignition system (DIS) diagnosis.

Cooling System:

Radiator, water pump, thermostat, cooling fan operation, coolant types and capacities.

Exhaust System:

Catalytic converter, muffler, exhaust pipes, oxygen sensors (O2 sensors).

Transmission Manual:

NV3550 5-speed manual transmission service, clutch inspection and replacement, gear shift linkage adjustment.

Transmission Automatic:

42RLE 4-speed automatic transmission service, torque converter, transmission fluid change and filter replacement.

Transfer Case:

NP231 Command-Trac 2-speed transfer case service, fluid types and capacities, operation modes.

Drivetrain Axles:

Dana 30 front axle, Dana 35c rear axle (optional for some trims), differential service, axle seal replacement, U-joint service.

Suspension Front:

Solid front axle, coil springs, shock absorbers, control arms, track bar, steering damper.

Suspension Rear:

Solid rear axle, coil springs, shock absorbers, control arms, track bar.

Steering:

Power steering system, steering gearbox, tie rods, drag link, steering column.

Brakes Front:

Front disc brakes, rotor and pad replacement, caliper service.

Brakes Rear:

Rear disc brakes (standard on most 2002 models), rotor and pad replacement, caliper service.

Brake System General:

Brake fluid type and bleeding procedures, master cylinder, brake booster, ABS system (if equipped).

Electrical System Overview:

12-volt negative ground system, battery, charging system (alternator), starting system (starter motor).

Lighting System:

Headlights, taillights, turn signals, interior lighting, bulb replacement.

Instrument Panel:

Gauges, warning lights, driver information center.

Body Exterior:

Body panel removal and installation, door mechanisms, hood, tailgate, convertible top service, fenders, bumpers.

Body Interior:

Seat removal, dashboard disassembly, interior trim panels, carpeting.

HVAC System:

Air conditioning, heater core, blower motor, refrigerant handling, system diagnosis.

Safety Systems:

Airbag system components and diagnosis (if applicable), seatbelt mechanisms.

Wiring Diagrams:

Comprehensive electrical circuit diagrams for all major systems.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules for oil changes, filter replacements, fluid checks, and other routine services.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon problems.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation for all major systems.

Diagnostics:

Diagnostic trouble codes (DTCs) and their meanings, sensor testing, actuator testing.

Engine Rebuild:

Complete engine overhaul procedures, including torque specifications, clearances, and assembly sequences.

Transmission Overhaul:

Detailed instructions for transmission disassembly, inspection, repair, and reassembly.

Brake System Service:

Brake bleeding, pad and rotor replacement, caliper rebuilding, ABS component testing.

Electrical Component Replacement:

Instructions for replacing sensors, actuators, control modules, lights, and other electrical components.

Body And Frame:

Procedures for body panel alignment, rust repair, convertible top maintenance, and frame inspection.

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes and filter replacements to full engine and transmission overhauls, electrical diagnostics, and bodywork.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely searchable text (if professionally scanned/created)

Print Quality

Image Resolution:

Expected high-resolution images and diagrams suitable for printing.

Binding Type

Digital Access:

Downloadable

Paper Type

Physical Equivalent:

Comparable to original manufacturer's dealership workshop manuals (high-quality paper).

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

4.0L (242 cu in) OHV I6 (PowerTech)

Engine Option 2:

2.5L (150 cu in) OHV I4 (AMC 150)

Performance

4.0L Horsepower:

190 hp @ 4,600 rpm

4.0L Torque:

235 lb-ft @ 3,200 rpm

2.5L Horsepower:

119 hp @ 4,800 rpm

2.5L Torque:

145 lb-ft @ 3,000 rpm

Fuel System

Injection Type:

Multi-Port Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Option 1:

NV3550 5-speed Manual

Optional

Transmission Option 2:

42RLE 4-speed Automatic

Features

Clutch Type:

Hydraulic clutch actuation

Automatic Features:

Electronically controlled, Overdrive gear

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

160.0 inches (4064 mm)

Width:

66.5 inches (1689 mm)

Height:

71.8 inches (1824 mm) (with hardtop)

Weights

Curb Weight Approx:

3500-3800 lbs (1588-1724 kg), varies by configuration

Towing Capacity:

2000 lbs (907 kg)

Payload Capacity:

850 lbs (386 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Likely 4-star (as per typical TJ ratings), though specific 2002 data may vary.

Active Features

Optional Anti-lock Braking System (ABS) on rear wheels, potentially all four for some trims.

Passive Features

Airbags:

Driver and passenger front airbags

Seat Belts:

3-point front seat belts, 2-point rear seat belts (center), 3-point rear seat belts (outboard).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player (optional), speaker configurations vary by trim.

Driver Assistance

ABS Availability:

Optional ABS on rear or all four wheels, depending on configuration.

Connectivity

Wiring Harnesses:

Standard automotive wiring harnesses for accessories and system integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Spark Plug Replacement 4.0L:

Approximately every 100,000 miles (160,000 km) with modern spark plugs (e.g., NGK).

Fluid Specifications

Engine Oil 4.0L:

SAE 10W-30 (API SG or higher), capacity 5 quarts (4.7 liters) with filter. Refer to manual for specific API classification.

Engine Oil 2.5L:

SAE 10W-30 (API SG or higher), capacity 5 quarts (4.7 liters) with filter. Refer to manual for specific API classification.

Transmission Fluid Manual:

NV3550: SAE 75W-90 GL-3 or GL-4 gear oil.

Transmission Fluid Automatic:

42RLE: ATF+4 (MS-9602), capacity approx. 4.5 quarts (4.3 liters) dry fill.

Transfer Case Fluid:

NP231: ATF+4 (MS-9602) or Dexron III, capacity approx. 1.5 quarts (1.4 liters).

Coolant:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Prediluted 50/50 mix. Capacity approx. 10.3 quarts (9.7 liters).

Brake Fluid:

DOT 3.

Known Issues

Common Issue 1:

Cracked exhaust manifolds (especially 4.0L)

Common Issue 2:

Oil filter adapter housing leaks (4.0L)

Common Issue 3:

Worn steering components (tie rod ends, drag link)

Common Issue 4:

Rear main crankshaft seal leaks (4.0L)

Common Issue 5:

Leaf spring perches cracking (less common on TJ than YJ, but possible with heavy off-roading)

Common Issue 6:

Heater core leaks

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Direct descendant of the original Willys MB military Jeep, embodying ruggedness and off-road prowess.

Model Evolution

Tj Generation Intro:

Introduced in 1997, replacing the YJ generation. Key evolution included coil springs instead of leaf springs for improved ride and articulation.

Tj Distinctive Features:

Return to round headlights, coil spring suspension, improved interior comfort over YJ.

Production

Production Period:

1997-2006

Manufacturing Plant:

Toledo North Complex, Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Capability Awards:

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