🏷️ Basic Information

Make:

Jeep

Model:

Wrangler

Generation:

TJ

Model Year:

2002

👋 Introduction

Vehicle Segment:

Compact SUV / Off-road Vehicle

Target Audience:

Enthusiasts, off-roaders, DIY mechanics, fleet owners.

Key Competitors:

Toyota 4Runner, Ford Bronco (previous generations), Suzuki Samurai (previous generations), Land Rover Defender (previous generations).

Design Philosophy:

Body-on-frame construction, solid front and rear axles (standard on most TJ models), removable doors and top, legendary off-road capability.

Manual Value Proposition:

Provides comprehensive, dealership-level repair information for owners who want to maintain and repair their TJ themselves, saving significant costs.

📋 Manual Details

Engine Coverage:

All gasoline engines for 2002 model year.

Transmission Coverage:

All manual and automatic transmissions offered for 2002.

Chassis Coverage:

Frame, suspension, steering, brakes, wheels, and tires.

Electrical Coverage:

Wiring diagrams, lighting, ignition, starting, charging, accessories, and body electronics.

Body Coverage:

Exterior and interior body panels, doors, seats, convertible top systems, and climate control.

Diagnostics Coverage:

Troubleshooting guides and diagnostic procedures for all major systems.

Estimated Page Count:

1500-2000 pages (typical for comprehensive service manuals of this era).

Manual Classification:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (likely PDF)

File Format Detail:

Searchable PDF, allowing for quick keyword-based navigation.

📖 Manual Coverage

Powertrain Systems:

Engine mechanical, engine cooling, engine fuel, engine ignition, engine lubrication, emissions control, starting and charging systems.

Drivetrain Systems:

Clutch, manual transmission, automatic transmission, transfer case, drive shafts, axles, differentials.

Suspension Steering Brakes:

Front and rear suspension, steering system, hydraulic brake system, parking brake system.

Electrical Electronic Systems:

Instrument cluster, lighting systems, horn, wipers/washers, power windows/locks, audio system, security system, engine control module (ECM), body control module (BCM).

Body Chassis Systems:

Frame, body mounting, doors, hood, tailgate, bumpers, seats, interior trim, convertible top, climate control system.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotation, spark plug replacement, belt inspection and replacement.

Diagnostic Procedures:

Troubleshooting charts for common symptoms, electrical system diagnostics using wiring diagrams, OBD-II diagnostics.

Repair And Overhaul:

Engine disassembly and assembly, transmission overhaul, brake system component replacement, suspension and steering component replacement, electrical component repair.

Component Replacement:

Detailed instructions for replacing virtually all serviceable components.

Specifications And Tolerances:

Torque specifications, clearances, fluid capacities, wear limits for all major components.

Diagnostic Complexity:

Advanced diagnostics with detailed wiring diagrams and fault code interpretation.

Rebuild Procedures:

Comprehensive step-by-step instructions for complete engine and transmission rebuilds.

Special Tools:

Identification and usage instructions for specialized tools required for specific repairs.

Troubleshooting Methodology:

Structured approach to diagnosing issues, starting with basic checks and progressing to complex electrical tracing.

📊 Manual Specifications

Image Resolution:

High-resolution, suitable for clear viewing of diagrams and illustrations.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code 2002 4 0L:

ERH (4.0L Inline 6-cylinder)

Engine Displacement 4 0L:

3952 cc (241 cu in)

Engine Configuration 4 0L:

Inline 6-cylinder, Overhead Valve (OHV)

Horsepower 4 0L:

190 hp @ 4600 rpm (approximate)

Torque 4 0L:

235 lb-ft @ 3200 rpm (approximate)

Engine Code 2002 2 5L:

ENJ (2.5L Inline 4-cylinder)

Engine Displacement 2 5L:

2464 cc (150 cu in)

Engine Configuration 2 5L:

Inline 4-cylinder, Overhead Valve (OHV)

Horsepower 2 5L:

117 hp @ 4800 rpm (approximate)

Torque 2 5L:

145 lb-ft @ 3200 rpm (approximate)

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) for 4.0L, Conventional Distributor for 2.5L.

🔧 Transmission

Standard Transmission Type:

5-Speed Manual Transmission (NV3550 for 4.0L, AX-15 for 2.5L in earlier TJs, but NV3550 likely for 2002 2.5L as well)

Optional Transmission Type:

4-Speed Automatic Transmission (42RLE)

Transfer Case:

Command-Trac NV231 (standard), optional: Selec-Trac NV242 (with full-time 4WD option).

Transfer Case Gear Ratios:

NV231: 2.72:1 low range. NV242: 2.72:1 low range.

Manual Transmission Fluid:

NV3550: Mopar Manual Transmission Lubricant (MS-9070) or equivalent SAE 75W-90 synthetic. AX-15: ATF+4 (MS-9602) or equivalent SAE 75W-90 synthetic.

Automatic Transmission Fluid:

ATF+4 (MS-9602)

Transfer Case Fluid:

NV231/NV242: NP-136/149 Transfer Case Fluid (MS-9602) or equivalent Automatic Transmission Fluid (ATF+4).

📐 Dimensions

Wheelbase 2 Door:

93.4 inches (2372 mm)

Overall Length 2 Door:

151.3 inches (3843 mm)

Overall Width 2 Door:

66.5 inches (1689 mm)

Overall Height 2 Door:

71.0 inches (1803 mm) (soft top)

Curb Weight Approx:

3,300 - 3,700 lbs (1497 - 1678 kg) depending on configuration

🛡️ Safety Features

NHTSA Rollover Resistance:

3-star rating (typical for SUVs of this era)

Braking System:

Front disc brakes, rear drum brakes (standard). Optional ABS on rear wheels for some configurations.

Airbags:

Driver and passenger front airbags.

💡 Technology Features

Audio System:

Factory AM/FM/CD player (optional premium audio system with amplifier and subwoofer available).

Cruise Control:

Available on most models.

Factory Phone Integration:

Not typically equipped with factory Bluetooth or advanced smartphone integration.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (using synthetic oil can extend this).

Engine Air Filter Replacement:

Every 15,000 miles or 12 months, or as needed based on driving conditions.

Spark Plug Replacement:

4.0L: Every 100,000 miles (using specific long-life plugs); 2.5L: Typically 30,000-60,000 miles depending on plug type.

Engine Oil Capacity 4 0L:

5.7 quarts (5.4 liters) with filter change.

Engine Oil Type 4 0L:

SAE 10W-30 (preferred for most conditions). Consult manual for specific temperature ranges and synthetic options.

Engine Coolant:

Mopar Antifreeze/Coolant (MS-9769) or equivalent HOAT (Hybrid Organic Acid Technology) coolant, typically a 50/50 mix with distilled water.

Power Steering Fluid:

Mopar Power Steering Fluid (MS-5901) or equivalent ATF+4 (MS-9602).

Common Tj Issues:

Crankshaft position sensor failures (leading to no-start), exhaust manifold cracks (especially on 4.0L), water pump leaks, radiator leaks, rear main seal leaks, clutch wear, interior accessory failures (window regulators, HVAC controls).

Rust Concerns:

Frame rust, particularly around the motor mounts and suspension attachment points, is a significant concern for TJ models, especially those in rust-belt states or coastal areas.

📚 Vehicle History

Jeep Legacy:

Jeep has a long-standing reputation for producing rugged, capable off-road vehicles dating back to World War II with the original Willys MB.

Tj Introduction:

The TJ Wrangler was introduced for the 1997 model year, replacing the YJ generation. It marked a return to the classic round headlights and coil-spring suspension, a significant departure from the YJ's leaf springs.

Tj 2002 Updates:

For 2002, key updates included the introduction of the NV3550 5-speed manual transmission for the 4.0L engine, replacing the AX-15. Minor interior and exterior styling tweaks may have been present.

Assembly Location:

Toledo North Assembly, Toledo, Ohio, USA.

🏆 Awards & Recognition

Off Road Capability Recognition:

Consistently lauded by automotive publications and off-road enthusiasts for its exceptional off-road prowess and iconic design.