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2002 Jeep Wrangler Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 👋 Introduction Market Position Jeep Wrangler Position: Iconic off-road focused SUV, renowned for its go-anywhere capability and rugged design. The...
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2002 Jeep Wrangler Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Year:
2002
👋 Introduction
Market Position
Jeep Wrangler Position:
Iconic off-road focused SUV, renowned for its go-anywhere capability and rugged design. The 2002 model represents the TJ generation's evolution.
Competitive Analysis
Competitors:
Ford Bronco (prior generation), Toyota 4Runner, Chevrolet Blazer, Land Rover Defender (less direct competitor due to price and focus).
Key Features
Design:
Classic Jeep styling, removable doors and top, solid front axle, high ground clearance, short wheelbase.
Capability:
Exceptional off-road articulation and traction, robust chassis and drivetrain.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Workshop Manual
Language:
English
Format:
Digital (PDF)
Page Count
Estimated Page Count:
1000+
📖 Manual Coverage
Systems Covered
Engine:
2.4L (148 CID) Power Tech DOHC I-4 Engine (less common for this year but may be covered)
Transmission:
42RLE 4-Speed Automatic Transmission
Drivetrain:
Dana 35 Rear Axle (C-clip)
Suspension:
Rear: Solid Live Axle with Leaf Springs and Control Arms
Brakes:
Rear: Disc Brakes
Steering:
Recirculating Ball Steering System
Electrical:
12V System, Charging System, Ignition System, Lighting, Gauges, Instrumentation, Power Accessories
Body:
Body Panels, Doors, Hood, Fenders, Bumpers, Soft Top/Hardtop Systems
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) System
Interior:
Seats, Dashboard, Trim Panels, Interior Lighting
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks and Replenishment, Spark Plug Replacement, Belt Inspection and Replacement
Troubleshooting:
Diagnostic Procedures, Symptom-Based Troubleshooting Charts, Electrical Schematics for Diagnosis
Repair:
Engine Mechanical and Electrical Repair, Transmission Overhaul and Repair, Drivetrain Component Replacement, Suspension and Steering Component Repair, Brake System Repair, HVAC System Repair, Body Panel Repair
Diagnostics:
OBD-II Diagnostics, Diagnostic Trouble Codes (DTCs) Interpretation and Resolution
Wiring:
Complete Electrical Wiring Diagrams for All Systems
Technical Depth
Depth:
Comprehensive Engine Rebuild Procedures, Detailed Transmission Overhaul Steps, In-depth Electrical System Diagnosis and Repair, Body and Chassis Component Repair
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text Content
Printability:
Printable Pages
Print Quality
Resolution:
High-Resolution Images and Diagrams
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
136 (4.0L I6)
Engine Type:
4.0L OHV Power Tech I-6
Displacement:
3952 cc (242 cubic inches)
Bore X Stroke:
3.875 in x 3.562 in (98.4 mm x 90.5 mm)
Compression Ratio:
8.75:1
Horsepower Gross:
190 hp @ 4600 rpm
Torque Gross:
235 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Oil
Oil Capacity:
5 US Quarts (4.7 Liters) with filter
Recommended Oil Viscosity:
10W-30
Cooling System
Coolant Capacity:
10.7 US Quarts (10.1 Liters)
🔧 Transmission
Standard
Transmission Type:
NV3550 5-Speed Manual
Optional
Transmission Type:
42RLE 4-Speed Automatic
Features
Manual Transmission Fluid Type:
NV3550 Manual Transmission Fluid (Specific Mopar Specification)
Automatic Transmission Fluid Type:
ATF+4 (Mopar)
Transfer Case Fluid Type:
NP241 GII Command-Trac: Mopar Dexron III/Mercon ATF or equivalent
📐 Dimensions
Exterior
Wheelbase:
93.4 inches (2372 mm)
Length:
151.9 inches (3858 mm)
Width Body:
66.7 inches (1694 mm)
Height To Top Of Body:
70.2 inches (1783 mm)
Ground Clearance:
Approx. 8.7 inches (221 mm) unloaded
Weights
Curb Weight Manual:
Approx. 3,335 lbs (1513 kg)
Curb Weight Automatic:
Approx. 3,435 lbs (1558 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 4,500 lbs (2041 kg)
Towing Capacity:
2,000 lbs (907 kg) with trailer brakes
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
Not Specifically Rated (as per common practice for low volume SUVs of that era)
NHTSA Passenger Front Impact:
Not Specifically Rated
Active Features
ABS:
Standard on all models (4-wheel disc ABS)
Passive Features
Airbags:
Driver and Passenger Frontal Airbags
Seatbelts:
3-Point Front Seatbelts, Lap Belts for Rear Occupants (if equipped)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player (optional), cassette player (standard/optional).
Speakers:
Standard 2-speaker or optional 4-speaker system.
Driver Assistance
ABS:
Standard 4-wheel ABS.
Connectivity
Bluetooth:
Not available from factory.
Aux Input:
Not available from factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles (or 3-6 months) depending on driving conditions (severe service requires more frequent changes).
Engine Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plug Replacement:
Approximately 100,000 miles (using original equipment spark plugs).
Transmission Fluid Change Manual:
Typically no scheduled change interval, but inspect for leaks and condition. Consider replacement at higher mileage or if experiencing issues.
Transmission Fluid Change Automatic:
Every 30,000 - 60,000 miles, depending on driving conditions.
Transfer Case Fluid Change:
Every 30,000 - 60,000 miles.
Differential Fluid Change:
Every 30,000 - 60,000 miles.
Fluid Specifications
Engine Oil Spec:
API Certified SAE 10W-30
Coolant Spec:
Mopar Antifreeze/Coolant (Green) or equivalent ethylene glycol based coolant with corrosion inhibitors.
Brake Fluid Spec:
DOT 3
Known Issues
Common Problems Engine:
Oil filter housing leaks, distributor cap/rotor wear, thermostat issues, rear main seal leaks.
Common Problems Drivetrain:
Dana 35 axle C-clip concerns (especially under heavy off-road use), transfer case chain stretch, clutch wear (manual transmission).
Common Problems Suspension:
Leaf spring sag, worn control arm bushings, track bar wear.
Common Problems Electrical:
Wiring harness chafing, alternator issues, instrument cluster problems.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep's heritage dates back to WWII with the iconic Willys MB. The Wrangler is the spiritual successor to the CJ series, representing continuous development of the rugged, off-road vehicle.
Model Evolution
Tj Generation:
The 2002 Wrangler is part of the TJ generation (1997-2006), which marked a significant departure from the YJ by returning to the coil-spring suspension front axle and a unibody construction (except for the frame rails).
Production
Manufacturing Location:
Toledo, Ohio, USA
Production Years:
The TJ Wrangler was produced from 1997 to 2006 model years.
🏆 Awards & Recognition
Recognitions
Off Road Magazine:
Consistently recognized by off-road enthusiasts and publications for its exceptional capability and heritage.
Vehicle History:
The TJ Wrangler is often cited as a benchmark for compact, off-road-capable SUVs. Its popularity endures among enthusiasts and collectors.
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