Jeep Wrangler 2002 Digital Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Codes Platform: TJ 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Usp: Renowned for its exceptional off-road capability,...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Codes

Platform:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Renowned for its exceptional off-road capability, iconic design, and robust construction.

Competitive Analysis

Competitors:

Toyota 4Runner, Land Rover Discovery, Ford Bronco (earlier generations)

Key Features

Design:

Body-on-frame construction, solid front and rear axles, removable doors and roof (soft top or hardtop).

Off Road Packages:

Available in various trims, with the Rubicon model featuring enhanced off-road hardware like electronic locking differentials and a disconnecting sway bar.

📋 Manual Details

Coverage Areas

Engine Variants:

4.0L I6 (AMC 242), 2.5L I4 (AMC 150)

Trim Levels:

SE, Sport, Sahara, Rubicon

Page Count

Estimated Pages:

Over 1500

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (4.0L I6, 2.5L I4), Transmission (AX-15, NV3550, NP242, NP231), Drivetrain (Dana 30, Dana 35c, Dana 44)

Chassis:

Suspension (Solid Axles, Coil Springs), Steering, Brakes (Front Disc/Rear Drum, Front & Rear Disc on Rubicon), Exhaust

Electrical:

Wiring Diagrams, Lighting, Ignition, Charging System, Starting System, Instrument Cluster, HVAC Controls, Power Accessories

Body And Frame:

Body Panels, Doors, Hood, Tailgate, Interior Trim, Frame Inspection and Repair

Procedures Included

Maintenance:

Fluid Changes (Oil, Coolant, Brake, Transmission, Differential), Filter Replacements, Lubrication, Belt and Hose Inspection

Diagnostics:

Troubleshooting Guides, Symptom-Based Diagnostics, DTC (Diagnostic Trouble Code) Interpretation and Resolution

Repair:

Engine Overhaul, Transmission Rebuild, Differential Service, Brake Component Replacement, Suspension Component Replacement, Electrical Component Repair

Special Procedures:

Torque Specifications, Alignment Procedures, Welding and Fabrication Guidelines, Rubicon Locker System Service

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid checks and filter changes to complete engine and transmission overhauls, including advanced diagnostic procedures.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Searchability:

Fully searchable text for quick information retrieval.

Illustrations:

Includes detailed diagrams, schematics, and photographs for clear understanding of procedures.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

4.0L Inline-6 (AMC 242)

Engine 1 Displacement:

3960 cc (242 cubic inches)

Engine 1 Configuration:

OHV, 12-valve

Engine 1 Horsepower:

190 hp @ 4600 rpm

Engine 1 Torque:

235 lb-ft @ 3200 rpm

Secondary Engine

Engine 2 Variant:

2.5L Inline-4 (AMC 150)

Engine 2 Displacement:

2500 cc (150 cubic inches)

Engine 2 Configuration:

OHV, 8-valve

Engine 2 Horsepower:

119 hp @ 4700 rpm

Engine 2 Torque:

145 lb-ft @ 3000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) on 4.0L, Distributor Ignition System on 2.5L

🔧 Transmission

Standard

Transmission Type 1:

5-Speed Manual (NV3550 on 4.0L, AX-15 on 2.5L)

Optional

Transmission Type 2:

4-Speed Automatic (42RLE)

Features

Transfer Case Standard:

Command-Trac (NV231) - Part-Time, 2-High, 4-High, Neutral, 4-Low

Transfer Case Optional:

Selec-Trac (NV242) - Full-Time 4x4 option, 2-High, 4-High (Full-Time), 4-High (Part-Time), Neutral, 4-Low

Transfer Case Rubicon:

Rock-Trac (NV241OR) - 4:1 low-range gear ratio, part-time 4WD

Fluid Specs

Manual Transmission Fluid:

MS-9224 (or equivalent Dexron III/Mercon for some earlier models) - Check Manual for Specificity

Automatic Transmission Fluid:

ATF+4 (MS-9602)

Transfer Case Fluid:

MS-9417 (or equivalent NP231/242/241OR specific fluid)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width:

66.5 inches (1689 mm)

Height:

71.3 inches (1811 mm) (with hardtop)

Weights

Curb Weight:

Approx. 3,500 - 3,900 lbs (1588 - 1769 kg)

Gross Vehicle Weight Rating Gvw:

Approx. 4,800 - 5,100 lbs (2177 - 2313 kg)

Cargo

Cargo Volume Behind Front Seats:

Approx. 47.9 cu ft (1356 L)

Cargo Volume Behind Rear Seats:

Approx. 15.2 cu ft (430 L)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star (check specific configurations)

Active Features

Brakes:

Front disc, rear drum (standard); Front and rear disc (Rubicon)

Available on some models/trims

Passive Features

Airbags:

Driver and passenger front airbags

Seat Belts:

3-point front seat belts, lap belts for rear passengers

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD or Cassette player with optional premium sound system. Speaker configurations varied by trim.

Climate Control:

Manual HVAC controls with optional Air Conditioning.

Driver Assistance

Cruise Control:

Available as an option on most trims.

Anti Lock Brakes:

Optional on most models, standard on Rubicon.

Connectivity

Connectivity Features:

Limited by era; primarily focused on basic audio connectivity. No integrated Bluetooth or USB ports from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, depending on driving conditions (refer to manual for specifics).

Coolant Change Interval:

Every 30,000 miles or 2 years.

Transmission Fluid Change Interval:

Manual: 60,000 miles; Automatic: 45,000 - 60,000 miles (severe duty may require sooner).

Differential Fluid Change Interval:

Every 30,000-50,000 miles, or more frequently for off-road use.

Fluid Specifications

Engine Oil Specification:

SAE 10W-30 (API Service SG or higher) for both engines.

Coolant Specification:

Mopar Antifreeze/Coolant (OAT - Organic Additive Technology) or equivalent, mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 3

Power Steering Fluid:

MS-5901 (or equivalent ATF+4)

Known Issues

Common Issues Tj:

Cracked exhaust manifolds (especially on 4.0L), rear main seal leaks, axle housing bending (under extreme off-road use), HVAC blend door actuator failure, water pump leaks.

Common Maintenance Items:

Regularly check for vacuum leaks, inspect drive shafts and U-joints for wear, clean battery terminals, check tire pressure.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a rich heritage dating back to WWII, synonymous with ruggedness and off-road capability.

Model Evolution

Tj Generation:

The TJ Wrangler (1997-2006) marked a significant evolution with the introduction of coil springs for improved ride quality and on-road manners while retaining solid axles.

Rubicon Introduction:

The Rubicon trim was introduced in 2003, significantly enhancing its off-road prowess.

Production

Manufacturing Location:

Toledo, Ohio, USA

Production Years:

1997-2006 (for TJ generation)

🏆 Awards & Recognition

Recognitions

Off Road Accolades:

Consistently rated among the top off-road vehicles for its class and capability.

Ratings

Consumer Ratings:

Praised for its go-anywhere ability and iconic styling, though often criticized for on-road comfort and fuel economy.

Certifications

Epa Fuel Economy:

Approximately 15-17 MPG city / 17-20 MPG highway, depending on engine and transmission.