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Jeep WRANGLER TJ Replacement Parts Manual 2002

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Year: 2002 Codes Chassis Code: TJ 👋 Introduction Market Position Positioning: Essential resource for Jeep Wrangler TJ owners and mechanics...
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Jeep WRANGLER TJ Replacement Parts Manual 2002
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Generation:
TJ
Year:
2002
Codes
Chassis Code:
TJ
👋 Introduction
Market Position
Positioning:
Essential resource for Jeep Wrangler TJ owners and mechanics who prioritize using genuine OEM parts for repairs and restorations. Caters to the DIY enthusiast and professional service centers.
Competitive Analysis
Comparison:
Superior to generic aftermarket parts catalogs due to its OEM specificity, ensuring perfect fitment and quality. Complementary to service manuals, providing the 'what' of parts, while service manuals provide the 'how' of repair.
Key Features
Features:
Illustrated exploded views, complete part number listings, identification of all original components, crucial for accurate ordering and sourcing.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive parts identification and listing for all major vehicle systems and components.
Page Count
Page Count:
Estimated 300-500 pages (typical for OEM parts catalogs of this era).
Manual Type
Type:
OEM Replacement Parts Manual / Parts Catalog
Language
Language:
English
Format
Format:
Illustrated with Exploded Parts Diagrams, Part Numbers Listed in Sections.
📖 Manual Coverage
Systems Covered
Engine:
Engine assembly, cylinder head, block, oil pump, lubrication system, cooling system, intake manifold, exhaust manifold, fuel system components, ignition system components.
Transmission:
Manual transmission (e.g., NV3550, AX-15), Automatic transmission (e.g., 32RH, 42RLE) components, transfer case (e.g., NP231, NP241) components, clutch system (if manual).
Drivetrain:
Front axle, rear axle (Dana 30, Dana 35c, Dana 44), driveshafts, universal joints, wheel hubs, differential components.
Suspension Steering:
Front suspension (solid axle, coil springs, control arms, track bar, sway bar), rear suspension (solid axle, coil springs, control arms, track bar, sway bar), steering gear, steering column, power steering system.
Brakes:
Front brakes (disc), rear brakes (disc or drum depending on configuration), master cylinder, brake booster, brake lines, parking brake system.
Electrical:
Wiring harnesses, engine control module (ECM) components, lighting (headlights, taillights, interior), instrument cluster, sensors, battery, alternator, starter motor, fuses, relays.
Body Exterior:
Body panels (fenders, hood, doors, quarter panels), bumpers, grille, windshield frame, soft top components, hardtop components, latches, hinges, mirrors, seals, trim.
Body Interior:
Seats, seat belts, dashboard components, center console, door panels, headliner, floor coverings, steering wheel, pedals, interior trim pieces, climate control vents.
Wheels Tires:
Wheel options, lug nuts, valve stems.
Procedures Included
Disassembly Assembly:
Detailed exploded views facilitating disassembly and reassembly of all listed components. Ideal for correct part ordering and installation procedures.
Part Identification:
Primary function is the precise identification of all original equipment manufacturer (OEM) part numbers for replacement purposes.
Technical Depth
Depth:
Focuses on parts identification and relationships. Does not typically include diagnostic procedures, repair techniques, or torque specifications, which are found in a Service Manual.
📊 Manual Specifications
File Format
File Format:
Likely a digital format (PDF) for easy searching and printing, or a physical bound book.
Print Quality
Print Quality:
High quality, designed for clear viewing of detailed diagrams and legible part numbers. OEM standard.
Binding Type
Binding:
If printed, typically bound with a durable cover, saddle-stitched or perfect bound for workshop use.
Paper Type
Paper Type:
If printed, durable, semi-gloss paper stock to withstand workshop environments and frequent use.
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.4L Inline-4 (97-02), 4.0L Inline-6 (97-06). This manual specifically covers the 2002 model year, which would include the 2.4L I4 and the 4.0L I6.
Performance
Engine 4.0L I6 Power:
Approximately 190 hp @ 4,600 rpm
Engine 4.0L I6 Torque:
Approximately 235 lb-ft @ 3,200 rpm
Fuel System
Fuel Injection:
Multi-point fuel injection (MPI)
Engine Codes
Engine 4.0L I6 Code:
ERH (for 2002)
Engine 2.4L I4 Code:
EDZ (for 2002)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission (New Venture Gear NV3550) was standard on many TJ models.
Optional
Optional Transmission:
4-speed automatic transmission (Chrysler 32RH for early TJ, 42RLE for later TJ models).
Features
Transfer Case Options:
New Process NP231 Command-Trac (2WD High, 4WD High, 4WD Low) standard. New Process NP241OR Rock-Trac (with lower gear ratio) optional on Rubicon models.
Fluid Specs
Manual Transmission Fluid:
Typically SAE 75W-90 synthetic gear lubricant (e.g., Mopar NV3550, API GL-5). Consult manual for exact specification.
Automatic Transmission Fluid:
Chrysler ATF+4 (Mopar designation) for 42RLE. Chrysler ATF+3 for 32RH.
📐 Dimensions
Exterior
Wheelbase 2 Door:
93.4 inches
Wheelbase 4 Door Unlimited:
Not applicable for 2002 TJ model, Unlimited (LJ) started in 2004.
Length 2 Door:
151.4 inches
Width 2 Door:
66.5 inches
Height 2 Door:
71.5 inches (with soft top)
Weights
Curb Weight 2 Door I6:
Approximately 3,500 - 3,700 lbs (depending on options)
Towing Capacity:
3,500 lbs (properly equipped)
Ground Clearance:
Varies by model and tire size, typically 8-10 inches for stock configurations.
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3-star (as per typical SUV ratings of the era; specialized off-road design can influence perception).
Active Features
ABS:
Available on some models, often rear-wheel ABS only.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Front seat shoulder belts, rear lap belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or AM/FM/CD player. Speaker configurations varied by trim level.
Driver Assistance
Cruise Control:
Available on some trim levels.
Connectivity
Auxiliary Input:
Rarely present from the factory; aftermarket solutions common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months (depending on usage and oil type). Consult owner's manual for precise intervals.
Tune Up Interval:
Spark plugs typically every 30,000-60,000 miles (depending on plug type); refer to owner's manual.
Fluid Specifications
Engine Oil Spec:
SAE 10W-30 for 4.0L I6, SAE 5W-30 for 2.4L I4 (check specific manual for details). API certified.
Coolant Spec:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT or equivalent orange coolant.
Brake Fluid Spec:
DOT 3 brake fluid.
Known Issues
Common Tj Issues:
Leaks (oil pan, valve cover, rear main seal), clutch wear (manual transmissions), AC system issues, dashboard crack, exhaust manifold cracks (especially on 4.0L), steering box wear, rear main seal leaks, transfer case chain stretch.
Part Numbers
Example Part Number Format:
Typically 8-digit numbers (e.g., 52037849AA for a specific component).
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long and storied history in off-road vehicles, dating back to World War II. The Wrangler is the direct descendant of the original Jeep CJ series.
Model Evolution
Tj Introduction:
The TJ Wrangler was introduced for the 1997 model year, replacing the YJ. It marked a significant return to the CJ's coil-spring suspension and a generally more refined, yet still rugged, platform.
Production
Tj Production Years:
1997-2006
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Reputation:
Consistently praised for its off-road capability and iconic design by automotive publications and enthusiasts.
Ratings
4X4 Magazine Ranking:
Often ranked highly by off-road focused publications for its segment.
Certifications
Oem Parts Standard:
This manual adheres to OEM (Original Equipment Manufacturer) standards for parts interchangeability and accuracy.
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