2002 Jeep Wrangler TJ Service Shop Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Model Code: TJ Year: 2002 Generation Generation Name: TJ Generation Years: 1997-2006 Codes Vin Code: 1J4... 👋 Introduction Market Position Market Position:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Model Code:

Year:

Generation

Generation Name:

Generation Years:

1997-2006

Codes

Vin Code:

1J4...

👋 Introduction

Market Position

Market Position:

The 2002 Jeep Wrangler TJ is a compact, highly capable off-road SUV, celebrated for its ruggedness and iconic open-air design. It caters to enthusiasts seeking adventure and utilitarian functionality.

Competitive Analysis

Competitive Analysis:

Competes against other off-road focused vehicles and compact SUVs, but its unique body-on-frame construction, solid axles (front and rear), and legendary Jeep capability set it apart.

Key Features

Key Features:

• Iconic Wrangler styling

• Removable doors and top

• Solid front and rear axles

• Command-Trac 2-speed transfer case

• Excellent off-road articulation and ground clearance

• Durable construction for off-road use

Manual Value Proposition

Manual Value Proposition:

This comprehensive workshop manual is an essential resource for owners and technicians to maintain, diagnose, and repair the 2002 Jeep Wrangler TJ. Its detailed procedures, diagrams, and specifications ensure accurate and efficient servicing.

📋 Manual Details

Coverage Areas

Coverage Areas:

• Body

• Chassis

• Electrical System

• Engine

• Transmission

• Drivetrain

• Suspension

• Steering

• Brakes

• HVAC

• Fuel System

• Exhaust System

• Ignition System

• Lubrication

• Cooling System

• Interior Trim

• Exterior Trim

• Wheels and Tires

• Maintenance

• Troubleshooting

• Diagnostics

• Wiring Diagrams

Page Count

Page Count:

Estimated 1000+ pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Service Shop Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

• 4.0L Inline 6-Cylinder Engine (PowerTech)

• 2.5L Inline 4-Cylinder Engine (SOHC)

• NV3550 5-Speed Manual Transmission

• 42RLE 4-Speed Automatic Transmission

• NP241OR / NV241OR Command-Trac Transfer Case

• Dana 30 Front Axle

• Dana 35C Rear Axle (with optional Trac-Lok or Pow-Lok differentials)

• ABS (Anti-lock Braking System)

• Power Steering System

• Air Conditioning (HVAC)

• Power Door Locks

• Power Windows (if equipped)

• Instrument Cluster and Gauges

• Lighting System (Exterior and Interior)

• Wiper/Washer System

• Ignition System

• Fuel Injection System (MPI)

• Cooling System

• Exhaust System

• Chassis components (frame, suspension, steering linkage)

• Body components (fenders, doors, hood, tailgate, bumpers)

• Interior components (seats, dashboard, trim panels)

• Electrical Distribution System

• Wiring Diagrams for all major systems

Procedures Included

Procedures Included:

• Routine Maintenance (oil changes, filter replacements, fluid checks)

• Scheduled Maintenance Intervals

• Engine Tune-Up and Diagnosis

• Engine Component Replacement (e.g., head gasket, water pump, alternator)

• Transmission Service and Repair

• Drivetrain Component Service (e.g., U-joints, differential service)

• Suspension Component Service and Alignment

• Brake System Service and Repair (e.g., pad/rotor replacement, caliper service)

• Steering System Service and Repair

• HVAC System Diagnosis and Repair

• Electrical System Troubleshooting and Repair

• Fuel System Diagnosis and Repair

• Exhaust System Repair

• Body Panel Repair and Alignment

• Interior Trim Removal and Installation

• Diagnostic Trouble Code (DTC) interpretation and troubleshooting

• Component Testing and Specifications

• Torque Specifications for critical fasteners

• Wiring Diagram interpretation and tracing

• Exploded Views and Part Identification

• Reassembly procedures

Technical Depth

Technical Depth:

Comprehensive (covers from basic maintenance to full engine/transmission rebuilds and complex electrical diagnostics)

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Fully Searchable Text

Bookmarking:

Fully Bookmarked for easy navigation

Print Quality

Print Quality:

High Resolution, suitable for printing

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Software Compatibility

Software Compatibility:

Windows XP, Vista, 7, 8, Linux, macOS

Source Document

Source Document:

Likely derived from OEM service manuals and technical bulletins.

⚙️ Engine Specifications

Primary Engine

Primary Engine Option:

4.0L OHV V6 (PowerTech)

Engine Displacement 4 0L:

3952 cc (241 cubic inches)

Engine Bore 4 0L:

3.875 in (98.4 mm)

Engine Stroke 4 0L:

3.375 in (85.7 mm)

Engine Compression Ratio 4 0L:

8.8:1

Engine Horsepower 4 0L:

190 hp @ 4600 rpm

Engine Torque 4 0L:

235 lb-ft @ 3200 rpm

Secondary Engine

Secondary Engine Option:

2.5L SOHC I4 (AMC 150)

Engine Displacement 2 5L:

2464 cc (150 cubic inches)

Engine Horsepower 2 5L:

119 hp @ 5200 rpm

Engine Torque 2 5L:

145 lb-ft @ 3800 rpm

Performance

Engine Cooling System:

Pressurized liquid cooling system

Fuel System

Fuel System Type:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Type Requirement:

Unleaded gasoline (87 octane minimum recommended)

Ignition System

Ignition System Type:

Distributorless Ignition System (DIS) with distributorless ignition module (DIM)

Lubrication

Oil Type 4 0L:

SAE 10W-30 API SJ or higher (check manual for specifics)

Oil Capacity 4 0L:

5 quarts (4.7 liters) with filter

Oil Type 2 5L:

SAE 5W-30 API SJ or higher (check manual for specifics)

Oil Capacity 2 5L:

5 quarts (4.7 liters) with filter

🔧 Transmission

Standard

Standard Transmission:

NV3550 5-Speed Manual Transmission

Optional

Optional Transmission:

42RLE 4-Speed Automatic Transmission

Features

Manual Transmission Features:

Robust design, suitable for off-road abuse, clutch operation

Automatic Transmission Features:

Electronically controlled, overdrive gear for highway efficiency

Fluid Specifications Manual

Manual Transmission Fluid Type:

Mopar Manual Transmission Lubricant (or equivalent DEXRON III/MERCON ATF for some applications - verify with manual)

Fluid Specifications Automatic

Automatic Transmission Fluid Type:

Mopar ATF+4 (or equivalent)

Fluid Capacity Manual

Manual Transmission Fluid Capacity:

2.1 quarts (2.0 liters)

Fluid Capacity Automatic

Automatic Transmission Fluid Capacity:

7.0 quarts (6.6 liters) for initial fill

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Overall Length:

150.0 inches (3810 mm)

Overall Width:

66.5 inches (1689 mm)

Overall Height:

66.4 inches (1687 mm) (soft top)

Ground Clearance:

approx. 8.0 inches (203 mm)

Weights

Curb Weight:

approx. 3,000 - 3,300 lbs (1360 - 1497 kg)

Gross Vehicle Weight Rating Gvwr:

approx. 4,300 lbs (1950 kg)

Cargo

Cargo Volume Behind Rear Seat:

approx. 13.1 cubic feet

Cargo Volume With Rear Seat Folded:

approx. 38.4 cubic feet

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3 out of 5 stars (typical for SUVs of this era)

IIHS Ratings:

Varies by test category and specific model year; consult IIHS for detailed reports.

Active Features

Active Safety Features:

• Optional Anti-lock Braking System (ABS)

• Power-assisted front disc brakes

• Rear drum brakes (standard)

Passive Features

Passive Safety Features:

• Seat belts with front pretensioners

• Child seat anchor points (LATCH system not standard on all 2002 models)

• Daytime Running Lights (DRLs)

• Roll bar structure integrated into windshield frame and B-pillars

💡 Technology Features

Infotainment

Infotainment System Standard:

AM/FM stereo with cassette player, optional CD player.

Speaker Configuration:

Typically 4 or 6 speakers (dashboard and roll bar mounted).

Driver Assistance

Driver Assistance Features:

Limited by era; primarily mechanical systems. Optional ABS.

Connectivity

Connectivity Options:

None (no Bluetooth, USB ports, or advanced smartphone integration).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months, whichever comes first (under normal driving conditions). Severe duty (off-roading, towing) may require more frequent changes.

Air Filter Replacement Interval:

Every 15,000 miles or 12 months.

Spark Plug Replacement Interval 4 0L:

Approximately every 100,000 miles (using appropriate spark plugs like Champion Copper Plus or equivalent).

Transmission Fluid Service Interval Automatic:

Every 30,000 miles or 36 months.

Transfer Case Fluid Service Interval:

Every 30,000 miles or 36 months.

Differential Fluid Service Interval:

Every 30,000 miles or 36 months.

Fluid Specifications

Coolant Type:

Mopar Antifreeze/Coolant (5/150) or equivalent HOAT (Hybrid Organic Acid Technology) coolant, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3.

Power Steering Fluid Type:

Mopar Power Steering Fluid or equivalent (Dexron III ATF can often be used, but consult manual).

Known Issues

Common Issues:

• Worn sway bar bushings and links

• Leaking valve cover gasket

• Oil filter adapter housing leaks

• Cracked exhaust manifold (especially on 4.0L)

• Radiator leaks

• Clutch wear (manual transmission)

• Transfer case chain stretch/wear

• Front axle U-joint failure

• Heater core leaks

• Stripped differential pinion threads (less common but possible)

• Rust formation on body panels, frame, and rocker panels

📚 Vehicle History

Brand Heritage

Brand Heritage:

Jeep's lineage traces back to World War II with the Bantam Reconnaissance Car, evolving into iconic civilian vehicles renowned for off-road prowess and ruggedness.

Model Evolution

Model Evolution Wrangler:

The Wrangler TJ, introduced in 1997, represented a significant modernization over its YJ predecessor. Key changes included the return to coil springs (from leaf springs) for improved ride quality and articulation, and a chassis design that maintained its off-road DNA.

Production

Production Location:

Toledo, Ohio, USA

Production Years Tj Model:

1997-2006

🏆 Awards & Recognition

Recognitions

Off Road Magazine Awards:

Consistently ranked highly by off-road publications for its capability.

Consumer Reports Ratings:

Ratings vary; known for reliability issues in some areas but praised for durability and off-road performance.

Certifications

Certifications:

Not applicable in the traditional sense; focuses on meeting automotive safety standards.