Vehicle Segment:
Compact SUV / Off-Road Vehicle.
Competitors:
Ford Bronco, Toyota 4Runner, Suzuki Samurai (at the time of its generation).
Off Road Capability:
Renowned for its rugged body-on-frame construction, solid axles, and short wheelbase, making it highly capable off-road.
Iconic Design:
Classic Jeep design with round headlights, seven-slot grille, and removable doors/top.
Target Audience:
Professional automotive technicians and advanced DIY enthusiasts.
Engine:
4.0L Power Tech I6 (2002 model year specific tuning, diagnostics, component repair).
Transmission:
NV3550 5-Speed Manual, 42RLE 4-Speed Automatic (disassembly, assembly, diagnostics, repair, fluid specifications).
Drivetrain:
NP231 Command-Trac Transfer Case, Dana 30 (front axle), Dana 35c (rear axle) specifications, maintenance, and repair procedures.
Suspension Steering:
Front coil spring solid axle, rear coil spring solid axle, steering system (gearbox, linkage), alignment specifications.
Brakes:
Front disc, rear drum braking system (component identification, overhaul, bleeding, ABS diagnostics if equipped).
Electrical:
Complete wiring diagrams, fuse box layouts, starter, alternator, battery, lighting, instrumentation, body control module (BCM) if applicable, diagnostic trouble codes (DTCs) and troubleshooting.
Body:
Body panel removal/installation, interior trim, soft top and hardtop service, doors, hood, tailgate, exterior trim.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling.
Maintenance:
Routine maintenance tasks: oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic flowcharts for common drivability, electrical, and mechanical issues.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems.
Diagnostics:
Detailed diagnostic procedures, including symptom-based troubleshooting and use of scan tools.
Depth:
Comprehensive, suitable for professional technicians and experienced DIYers. Covers complete engine rebuilds, transmission overhauls, electrical system diagnostics, and chassis repairs.
Engine Type:
Inline 6-Cylinder, SOHC
Engine Code:
AMC 242 / Power Tech I6
Displacement:
4.0 Liters (242 cubic inches)
Horsepower Gross:
190 hp @ 4600 rpm (approx.)
Torque Gross:
235 lb-ft @ 3200 rpm (approx.)
Fuel Delivery:
Multi-point Fuel Injection (MPI).
Recommended Fuel:
87 Octane Unleaded Gasoline.
ECU Type:
Chrysler's DRB-III diagnostic system (referenced in manual for troubleshooting).
Manual Transmission:
NV3550 5-Speed Manual
Automatic Transmission:
42RLE 4-Speed Automatic
Transfer Case:
NP231 Command-Trac (Part-time, 2WD, 4WD High, 4WD Low).
Manual Trans Fluid:
API GL-3 or GL-4 SAE 75W-90 Synthetic Gear Lubricant (specific brands and quantities detailed in manual).
Automatic Trans Fluid:
ATF+4 (MS-9602) (specific brands and quantities detailed in manual).
Transfer Case Fluid:
Mopar NV231 Spec or equivalent ATF+4 (specific brands and quantities detailed in manual).
Wheelbase:
93.4 inches (2372 mm)
Overall Length:
150.0 inches (3810 mm)
Overall Width:
66.7 inches (1694 mm)
Overall Height:
71.5 inches (1816 mm) (with hardtop)
Curb Weight:
Approx. 3,200 - 3,500 lbs (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 4,500 - 4,800 lbs
NHTSA Rollover Resistance:
3-star (as per typical NHTSA ratings for this era, specific to 2002 may vary slightly)
ABS:
Available (standard on some trims, optional on others).
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point front seatbelts, lap belts in rear (depending on configuration).
Oil Change:
Every 3,000 miles or 3 months, whichever comes first (severe duty/off-road recommended).
Air Filter:
Inspect every 15,000 miles, replace as needed.
Spark Plugs:
Replace every 60,000 - 100,000 miles (depending on plug type, refer to manual for exact spec).
Coolant Flush:
Every 30,000 miles or 2 years.
Engine Oil:
SAE 10W-30 API SJ or higher (e.g., Mopar SAE 10W-30).
Coolant:
Chrysler OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) type coolant, typically dark green or orange (e.g., Mopar 5 Year Coolant).
Brake Fluid:
DOT 3 or DOT 4 (Refer to specific cap on reservoir).
Common Problems:
Rear main seal leaks, radiator leaks, exhaust manifold cracks (especially on 4.0L), death wobble (steering stabilizer and component wear), clutch wear (manual transmission).
Common Problems Electrical:
Alternator failures, wiring harness chafing (especially near engine/suspension), instrument cluster issues.
Jeep Legacy:
Descendant of the original Willys MB military Jeep, known for ruggedness and off-road prowess since WWII.
Tj Generation:
The TJ Wrangler replaced the YJ generation and was produced from 1997 to 2006. It marked a return to the coil-spring suspension and round headlights, a significant departure from the YJ's leaf springs and square headlights.
Manufacturing Plant:
Toledo South Complex, Toledo, Ohio, USA.
Model Run:
1997-2006 (with specific updates for 2002 model year).
