Jeep Wrangler TJ 2002 Service Repair Workshop Manual

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

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Generation:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road Vehicle

Jeep Positioning:

Iconic off-road capability, ruggedness, open-air experience

Competitive Analysis

Competitors 2002:

Toyota Tacoma (SUV variant), Ford Bronco (previous gen), Land Rover Defender (less direct)

Key Features

Design Philosophy:

Classic Jeep design with modern improvements, removable doors and top, solid front axle (initially), coil spring suspension

Target Audience:

Off-road enthusiasts, outdoor adventurers, individuals seeking utility and ruggedness

📋 Manual Details

Coverage Areas

Primary Coverage:

Full Service and Repair

Secondary Coverage:

Maintenance, Diagnostics, Troubleshooting, Component Removal/Installation

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (Likely PDF, searchable)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, cooling system, lubrication system, fuel system, ignition system, emission control systems, engine diagnostics

Transmission Systems:

Manual transmission (NV3550), Automatic transmission (42RLE), clutch system, transfer case (NV241 GII)

Drivetrain Systems:

Front and rear axles (Dana 30, Dana 35), driveshafts, universal joints, locking differentials (if equipped)

Suspension Steering Systems:

Front and rear suspension (leaf springs, coil springs), shock absorbers, steering gear, power steering system, steering column

Brake Systems:

Front and rear brakes (disc and drum configurations), parking brake, Anti-lock Braking System (ABS) if equipped

Electrical Systems:

Battery, charging system, starting system, lighting, instruments, gauges, wipers, horn, power windows/locks (if equipped), infotainment, fuse box diagrams, wiring schematics

Body Chassis Systems:

Body construction, exterior trim, doors, hood, tailgate, seats, interior trim, body repair, frame inspection, rust prevention

HVAC Systems:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant handling, component diagnostics

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, brake pad replacement, belt inspections and replacement

Repair Procedures:

Engine rebuilds, transmission overhaul, clutch replacement, brake caliper rebuild, suspension component replacement, driveshaft repair, electrical component troubleshooting and replacement

Diagnostic Procedures:

OBD-II diagnostics, fault code interpretation, circuit testing, component testing, pressure testing

Troubleshooting Guides:

Step-by-step troubleshooting for common symptoms (e.g., no start, poor performance, strange noises)

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete overhaul and diagnostics)

Detail Level:

Detailed instructions, torque specifications, special tool requirements, diagnostic charts, wiring diagrams

📊 Manual Specifications

File Format

File Format:

PDF (Assumed high resolution, searchable text)

Print Quality

Print Quality:

High resolution graphics and text for clarity (if printed)

Binding Type

Binding Type:

Not applicable for digital format (N/A)

Paper Type

Paper Type:

Not applicable for digital format (N/A)

⚙️ Engine Specifications

Primary Engine

Engine Name:

2.4L DOHC I4 (Optional)

Engine Displacement I4:

2421 cc

Engine Horsepower I4:

150 hp @ 5200 rpm

Engine Torque I4:

170 lb-ft @ 3800 rpm

Engine Code I4:

Engine Name Standard:

4.0L OHV I6

Engine Displacement I6:

3957 cc

Engine Horsepower I6:

190 hp @ 4600 rpm

Engine Torque I6:

235 lb-ft @ 3200 rpm

Engine Code I6:

Performance

0-60 Mph I6 Auto:

Approx. 9.7 seconds

Towing Capacity:

2000 lbs (for 4-cyl) / 2000 lbs (for 6-cyl)

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

19 gallons

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual (NV3550)

Optional

Transmission Type Optional:

4-Speed Automatic (42RLE)

Features

Transfer Case:

2-Speed NV241 GII with Command-Trac part-time 4WD system

Clutch Type:

Dry single plate (for manual transmission)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches

Length:

151.4 inches

Width:

66.7 inches

Height:

70.0 inches

Weights

Curb Weight I6:

Approx. 3300-3500 lbs

Gross Vehicle Weight Rating:

Approx. 4600 lbs

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4 out of 5 stars (driver side)

Active Features

Optional (standard on some higher trims or later production)

Passive Features

Airbags:

Driver and passenger front airbags

Seatbelts:

3-point front and rear seat belts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium sound system. Base models may have AM/FM only.

Speaker Configuration:

Typically 4-6 speakers depending on trim level.

Driver Assistance

Driver Assistance Features:

Limited to optional ABS. No advanced electronic driver aids.

Connectivity

Connectivity Options:

No factory Bluetooth or USB connectivity. Aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Tire Rotation Interval:

Every 7,500 miles

Transmission Fluid Interval:

Manual: Inspect regularly, change as needed. Automatic: 30,000 - 60,000 miles (refer to manual).

Fluid Specifications

Engine Oil Spec:

SAE 10W-30 API SG or higher (for 4.0L I6); SAE 5W-30 API SG or higher (for 2.4L I4). Consult manual for precise specification.

Coolant Spec:

Chrysler OAT (Organic Additive Technology) coolant, typically a 50/50 mix with distilled water.

Transmission Fluid Manual:

NV3550: Mopar Manual Transmission Lubricant (or equivalent GL-3/GL-4 spec).

Transmission Fluid Automatic:

42RLE: ATF+4 (Mopar Automatic Transmission Fluid).

Transfer Case Fluid:

Mopar NV241 Transfer Case Lubricant (or equivalent GL-4 spec).

Brake Fluid Spec:

DOT 3.

Known Issues

Common Issues I6:

Head gasket leaks (especially on earlier 4.0L), oil filter adapter leaks, oil pan gasket leaks, cracked exhaust manifolds, distributorless ignition system (DIS) issues.

Common Issues Transmission:

NV3550 manual: clutch wear, potential for synchro issues. 42RLE automatic: occasional torque converter shudder or internal issues.

Common Issues Suspension:

Worn control arm bushings, worn track bar bushings (for coil spring models), shock absorber leaks, rust on frame and suspension components.

Common Issues Electrical:

Corrosion in wiring connectors, failure of interior lighting, HVAC blower motor resistor issues, power window/lock failures.

Common Issues Body:

Door seal leaks, tailgate leaks, cowl drain clogs leading to water ingress, frame rust, body mount deterioration.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Direct descendant of the original WWII Willys Jeep, known for off-road prowess and ruggedness since the 1940s.

Model Evolution

Tj Introduction:

The TJ generation was introduced for the 1997 model year, replacing the YJ Wrangler. It marked a significant shift with the return to round headlights and coil spring suspension.

Tj Updates 2002:

For 2002, the TJ Wrangler received minor updates including improved interior materials, updated HVAC controls, and optional side-impact airbags.

Production

Manufacturing Location:

Toledo Complex, Toledo, Ohio, USA

Tj Production Years:

1997-2006

🏆 Awards & Recognition

Recognitions

4X4 Magazine Recognition:

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

Ratings

Consumer Reports Rating:

Variable, often noted for off-road performance but average to below average in predicted reliability for certain components.

Certifications

Emission Standards:

Meets U.S. EPA and California ARB emission standards for 2002 model year vehicles.