Jeep WRANGLER TJ Factory Service Repair Manual 2002

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Generation: TJ Model Year: 2002 Codes Chassis Code: TJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Target Audience:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation:

Model Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Enthusiasts, off-roaders, and owners seeking to perform their own maintenance and repairs.

Competitive Analysis

Key Competitors Era:

Toyota 4Runner, Ford Bronco (previous generation), Chevrolet Blazer.

Key Features

Off Road Capability:

Renowned for its robust 4x4 systems, solid axles (front and rear), and high ground clearance, making it a benchmark in off-road performance.

Versatility:

Removable doors and roof contribute to its open-air driving experience and customization potential.

Simplicity Reliability:

The TJ generation is praised for its relatively simpler mechanical design compared to later models, contributing to its reputation for reliability and ease of maintenance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and maintenance for Jeep Wrangler TJ models.

Secondary Coverage:

Includes assembly, disassembly, troubleshooting, and technical specifications.

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive factory service manuals).

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical (assembly/disassembly), cooling system, fuel system, lubrication system, ignition system, emission control systems.

Drivetrain Systems:

Manual transmission, automatic transmission, transfer case, differentials (front and rear), driveshafts, axles.

Suspension Steering Brakes:

Front and rear suspension (coil springs, control arms, sway bars), steering system (gearbox, linkage), brake system (hydraulic, ABS if equipped), parking brake.

Electrical Systems:

Battery, charging system, starting system, lighting, instrumentation, body electrical (power windows, locks, wipers), powertrain control module (PCM), diagnostic trouble codes (DTCs).

Body Chassis:

Body panels, doors, hood, tailgate, interior trim, frame, underbody components.

Procedures Included

Maintenance Procedures:

Routine maintenance schedules, oil changes, fluid checks and changes, filter replacements, tune-ups, belt replacement.

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, and repair for all major vehicle systems.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, electrical circuit testing, use of diagnostic scan tools.

Assembly Disassembly:

Complete breakdown and reassembly instructions for major components and systems.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures including wiring diagrams, component testing specifications, and troubleshooting flowcharts.

Repair Complexity:

Covers everything from basic maintenance to complete engine and transmission overhauls, including specialized driveline and suspension repairs.

Specification Detail:

Includes torque specifications, clearances, alignment data, electrical resistance values, and other critical technical data.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Searchable text content for quick information retrieval.

Readability:

High-resolution scans or digital native format for clear diagrams and text.

Print Quality

Printability:

Printable pages for workshop use.

Binding Type

Physical Binding Type Example:

Spiral bound or comb bound for lay-flat use (if physical).

Paper Type

Physical Paper Type Example:

Durable, coated paper to withstand workshop conditions (if physical).

⚙️ Engine Specifications

Primary Engine

Engine Code:

4.0L Inline 6-Cylinder (MVP - Multi-Valve Performance)

Engine Displacement:

3952 cc (241 cubic inches)

Engine Design:

Overhead Valve (OHV) pushrod design, known for its torque and durability.

Performance

Horsepower Rating:

190 hp @ 4600 rpm

Torque Rating:

235 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Cooling

Cooling System Type:

Pressurized liquid cooling system

Engine Lubrication

Oil Type Specification:

API SJ or SL, SAE 10W-30 (refer to manual for exact specification based on climate)

Oil Capacity:

5.0 US quarts (4.7 liters) with filter change

🔧 Transmission

Standard Transmission

Type:

NV3550 5-Speed Manual Transmission

Optional Transmission

Type:

42RLE 4-Speed Automatic Transmission

Features

Transfer Case:

NV241OR 'Command-Trac' 2-speed part-time 4WD system with 2.72:1 low-range ratio.

Fluid Specifications Manual

Fluid Type:

Mopar Manual Transmission Lubricant (or equivalent SAE 75W-90 GL-3/GL-4)

Fluid Specifications Automatic

Fluid Type:

ATF+4 (Mopar)

📐 Dimensions

Exterior

Wheelbase Short Wheelbase:

93.4 inches (2372 mm)

Wheelbase Long Wheelbase:

103.4 inches (2626 mm) (typically for the Unlimited/LJ models, though 2002 primarily SWB)

Overall Length Swb:

151.4 inches (3845 mm)

Overall Width Swb:

66.7 inches (1694 mm)

Overall Height Swb Soft Top:

71.6 inches (1819 mm)

Weights

Curb Weight Approx:

3400-3700 lbs (1542-1678 kg) depending on configuration

Gross Vehicle Weight Rating Gvwr:

Approximately 4600-4800 lbs (2087-2177 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3-star (typical for early 2000s SUVs, especially high center-of-gravity vehicles).

Active Features

ABS Availability:

Available option, typically on higher trims or as part of a package.

Passive Features

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point front and rear seat belts (rear belts may vary by configuration).

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette and/or CD player, optional Infinity sound system.

Connectivity Early:

Limited connectivity by modern standards; often includes power outlets, antenna system.

Driver Assistance

Cruise Control Availability:

Available on higher trim levels or as an option.

Traction Control Availability:

Typically not available in 2002 model year TJ Wranglers; focus is on mechanical 4WD systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 6,000 miles or 6 months, whichever comes first (refer to manual for specific driving conditions).

Transmission Fluid Change Manual:

Recommended around 30,000 to 60,000 miles, or based on severe usage.

Transmission Fluid Change Automatic:

Recommended around 30,000 to 50,000 miles, or based on severe usage.

Coolant Change Interval:

Typically every 30,000 to 60,000 miles or 2-4 years.

Fluid Specifications

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

Mopar Power Steering Fluid (or equivalent ATF+4 compatible fluid)

Known Issues

Common Wear Items:

Ball joints, tie rod ends, sway bar links, control arm bushings, clutch wear (manual), clutch wear (automatic transmission).

Engine Oil Leaks:

Rear main crankshaft seal, valve cover gasket, oil pan gasket can be prone to leaks over time.

Cooling System Concerns:

Radiator, water pump, and heater core are wear items that may require replacement.

Transfer Case Chain Stretch:

The NV241OR transfer case chain can stretch over time, especially with aggressive off-road use, leading to slack.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long and storied history in the off-road vehicle segment, dating back to WWII Willys MB.

Model Evolution

Tj Generation 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.

Tj Key Changes 2002:

While 2002 was largely a carry-over year from previous TJ models, minor updates might include feature packaging and potentially slight revisions to available colors or trim options.

Production

Manufacturing Location:

Toledo, Ohio, USA

Production Years:

1997-2006

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized by off-road publications and enthusiasts for its capability and iconic design.

Ratings

Consumer Satisfaction General:

Generally high owner satisfaction, particularly for its off-road prowess and ruggedness.

Certifications

Emissions Certification:

Compliant with EPA and CARB emissions standards for the 2002 model year.