2002 Jeep WRANGLER TJ Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler TJ Year: 2002 Product Name: 2002 Jeep WRANGLER TJ Service & Repair Manual - PDF Codes Vin Decoder Prefix: 1J4 Generation Tj...

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标签: 2002 Car Cars Jeep Misc WRANGLER TJ

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler TJ

Year:

Product Name:

2002 Jeep WRANGLER TJ Service & Repair Manual - PDF

Codes

Vin Decoder Prefix:

Generation

Tj Generation Start Year:

Tj Generation End Year:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road Vehicle

Jeep Brand Focus:

Iconic off-road capability and ruggedness

Competitive Analysis

Key Competitors 2002:

Toyota Tacoma, Nissan Xterra, Ford Explorer (though often considered more refined)

Key Features

Defining Characteristics:

Solid front axle, removable doors and top, high ground clearance, robust 4x4 system

Manual Value Proposition:

Enables owners and technicians to perform all maintenance, diagnostics, and repairs efficiently and accurately.

📋 Manual Details

Coverage Areas

Engines Covered:

All 2002 Wrangler TJ engine variants

Models Covered:

All 2002 Wrangler TJ trim levels and configurations

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Classification:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagnostics, repair procedures, overhaul for all applicable engines

Engine Management:

Ignition system, fuel injection system, emission controls, sensors, actuators, ECU diagnostics

Transmission:

Manual and automatic transmission repair, clutch, driveline, transfer case servicing

Suspension:

Front and rear suspension systems, coil springs, shock absorbers, steering linkage

Brakes:

Hydraulic system, ABS (if equipped), brake pad/shoe replacement, rotor machining, caliper servicing

Electrical:

Wiring diagrams, fuse and relay identification, starter, alternator, battery, lighting systems, power windows, locks

Body And Frame:

Body panel repair, interior trim removal, doors, hood, tailgate, chassis diagnostics

HVAC:

Heating, ventilation, and air conditioning system repair, refrigerant handling, component replacement

Chassis:

Frame inspection and repair, exhaust system, fuel tank and lines

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotation, brake inspection

Diagnostic Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault code interpretation

Component Replacement:

Step-by-step instructions for replacing major and minor components

Rebuilding Procedures:

Detailed overhaul procedures for engines and transmissions

Specifications And Torques:

All necessary torque specifications, clearances, and measurements for repairs

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds

Diagnostic Capability:

Advanced diagnostic techniques, including interpreting sensor data and trouble codes

Special Tools:

Identification of required special tools and their usage

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable content for easy information retrieval

Printability:

Printable pages for workshop use

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding Method:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 2002:

42RLE (4-speed Automatic), NV3550 (5-speed Manual)

Engine Type:

Inline 6-cylinder, Overhead Valve (OHV)

Displacement 2002:

4.0 Liters (242 CID)

Performance

Horsepower 4.0L:

190 HP @ 4600 RPM

Torque 4.0L:

235 lb-ft @ 3200 RPM

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission (NV3550)

Optional

Optional Transmission Type:

4-Speed Automatic Transmission (42RLE)

Features

Transfer Case:

Selec-Trac NV241OR / Command-Trac NV231 (specific to trim)

Clutch Type:

Hydraulically actuated diaphragm spring clutch (manual)

Fluid Type Manual

Manual Transmission Fluid:

AXS4500 (or equivalent spec: SAE 75W-90 GL-3)

Fluid Type Auto

Automatic Transmission Fluid:

ATF+4 (Mopar)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Overall Length:

150.5 inches (3823 mm)

Overall Width:

66.5 inches (1689 mm)

Overall Height:

71.5 inches (1816 mm)

Ground Clearance:

10.2 inches (259 mm)

Weights

Curb Weight Manual:

Approx. 3250 lbs (1474 kg)

Curb Weight Automatic:

Approx. 3350 lbs (1519 kg)

Gross Vehicle Weight Rating:

Approx. 4500 lbs (2041 kg)

Cargo

Cargo Volume Behind Front Seats:

Approx. 40.0 cu ft (1.13 m³)

Cargo Volume Behind Rear Seats:

Approx. 15.0 cu ft (0.42 m³)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3 Star (based on older testing protocols)

Active Features

Optional on 2002 models (typically 4-wheel disc with rear drum)

Four Wheel Drive:

Standard full-time 4WD or part-time 4WD system (depending on transfer case option)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

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

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Infinity sound system.

Connectivity Options:

Basic analog systems, no integrated Bluetooth or USB in stock form.

Driver Assistance

Traction Control:

Limited, primarily mechanical (e.g., limited-slip differential on some models) or ABS-based for early systems.

Cruise Control:

Optional

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Transmission Fluid Change Auto:

Every 30,000 - 60,000 miles (refer to manual)

Transmission Fluid Change Manual:

Every 50,000 - 100,000 miles (refer to manual)

Coolant Flush:

Every 30,000 miles or 3 years (refer to manual)

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-30 or 10W-40

Engine Oil Capacity:

6 Quarts (5.7 Liters) with filter

Coolant Type:

Mopar OAT (Orange) or equivalent HOAT coolant (50/50 mix)

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Items:

Clutch wear, exhaust manifold cracks, suspension bushings, water pump leaks

Potential Electrical Gremlins:

Can occur due to age and exposure to elements, often related to grounds or connectors.

Transfer Case Chain Stretch:

Can lead to whining noises and driveability issues in older models.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Direct lineage from WWII Willys MB Jeep, known for off-road prowess.

Model Evolution

Tj Introduction:

Introduced in 1997 as a replacement for the YJ Wrangler, featuring coil springs for improved ride quality.

Tj Updates 2002:

2002 saw minor updates, continuing the established TJ platform.

Production

Production Location:

Toledo, Ohio, USA

Tj Production Years:

1997-2006

🏆 Awards & Recognition

Recognitions

Off Road Reputation:

Consistently ranked highly for off-road capability by automotive publications and enthusiasts.