Jeep Wrangler TJ 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Chassis Code: TJ Codes Platform: Jeep Wrangler (TJ) 👋 Introduction Market Position Market Segment: Compact Sport Utility Vehicle (SUV), renowned...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Chassis Code:

Codes

Platform:

Jeep Wrangler (TJ)

👋 Introduction

Market Position

Market Segment:

Compact Sport Utility Vehicle (SUV), renowned for its off-road capability and iconic design.

Competitive Analysis

Key Competitors 2002:

Toyota Tacoma (4x4), Nissan Xterra, Suzuki Vitara, Ford Bronco (earlier models).

Key Features

Design Philosophy:

Rugged, body-on-frame construction, solid front and rear axles (most models), removable doors and roof, open-air driving experience.

Offroad Capability:

Excellent ground clearance, approach/departure angles, available locking differentials (Rubicon trim), low-range gearing.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete mechanical and electrical service, repair, and maintenance for the 2002 Jeep Wrangler TJ.

Secondary Coverage:

Troubleshooting, diagnostics, wiring diagrams, body repair, and specifications.

Page Count

Page Count:

Estimated 1500+ pages (typical for comprehensive workshop manuals of this era).

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, internal components, cylinder head, block, pistons, crankshaft, camshaft, timing system, lubrication system, cooling system.

Engine Performance:

Fuel injection system, ignition system, emission control systems, turbocharger (if applicable), engine diagnostics and tuning.

Transmission Manual:

NV3550 manual transmission: disassembly, assembly, clutch system, gear shift mechanism, internal components.

Transmission Automatic:

42RLE automatic transmission: disassembly, assembly, torque converter, valve body, hydraulic system, electronic controls.

Drivetrain:

NP231/NV241OR (Command-Trac/Rubicon) transfer cases, Dana 30 front axle, Dana 35/Dana 44 rear axle, driveshafts, U-joints, axle seals, differentials.

Suspension:

Front and rear suspension systems: coil springs, shock absorbers, control arms, track bars, sway bars, bushings.

Steering:

Power steering system: pump, steering gear, steering column, tie rods, drag link, steering stabilizer.

Brakes:

Front and rear brake systems: disc brakes, brake calipers, rotors, brake pads, master cylinder, brake lines, parking brake system, ABS (if equipped).

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system (headlights, taillights, interior lights), fuse box, relays.

Instrumentation:

Instrument cluster: speedometer, tachometer, fuel gauge, temperature gauge, warning lights, onboard diagnostics (OBD-II).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system: A/C compressor, condenser, evaporator, heater core, blower motor, controls.

Body And Frame:

Body panels, doors, hood, tailgate, bumpers, interior trim, seats, soft top/hard top removal and installation, frame inspection and repair.

Chassis Electrical:

Power windows, power locks, wipers, horn, trailer wiring, cruise control.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotation, brake inspections, tune-ups.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting charts, electrical system diagnostics.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation for all major systems.

Diagnostics:

OBD-II scanner usage, diagnostic trouble codes (DTCs), component testing procedures.

Wiring Diagrams:

Complete and detailed electrical wiring diagrams for all vehicle systems.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed torque specifications, alignment data, and diagnostic procedures.

📊 Manual Specifications

File Format

File Format:

Searchability:

Text-searchable PDF for quick access to information.

Print Quality

Print Quality:

High-resolution, suitable for printing all pages.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4.0L Inline 6-Cylinder (MVP)

Engine Displacement:

3952 cc (242 cubic inches)

Engine Configuration:

OHV (Overhead Valve), Cast Iron Block, Aluminum Cylinder Head

Performance

Horsepower:

190 hp @ 4600 rpm

Torque:

235 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Engine Management

Jeep Powertrain Control Module (PCM)

🔧 Transmission

Standard

Transmission Type:

NV3550 5-Speed Manual Transmission

Optional

Transmission Type:

42RLE 4-Speed Automatic Transmission

Features

Clutch Type:

Hydraulic, Single Dry Plate

Transfer Case Standard:

NV231 Command-Trac (2WD/4WD Part-Time)

Transfer Case Optional:

NV241OR-HD (Dana 44) Rock-Trac (Rubicon trim) (2WD/4WD Part-Time with 4:1 low range)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

151.4 inches (3845 mm)

Width:

66.5 inches (1689 mm)

Height:

71.5 inches (1816 mm) (soft top)

Ground Clearance:

Approx. 8.5 inches (216 mm)

Weights

Curb Weight:

Approx. 3450-3700 lbs (1565-1678 kg) depending on configuration.

Towing Capacity:

2000 lbs (907 kg)

Payload Capacity:

Approx. 800-1000 lbs (363-454 kg)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

4-star driver, 4-star passenger (for 2002 model year).

Active Features

Available Anti-lock Braking System (ABS) on rear wheels.

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

3-point front seat belts, lap belts in rear.

💡 Technology Features

Infotainment

Stereo System:

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

Speakers:

Standard 4-speaker or optional 7-speaker system.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

OBD Ii:

Equipped with OBD-II diagnostic port for emissions and engine monitoring.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first.

Engine Oil Filter:

Replace with oil change.

Air Filter:

Inspect every 7,500 miles (12,000 km), replace as needed (typically every 15,000-30,000 miles).

Spark Plugs:

Replace every 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Type:

API Certified SAE 10W-30 (preferred), or SAE 5W-30 for extreme cold.

Engine Oil Capacity:

6 US quarts (5.7 liters) with filter.

Coolant:

Mopar OAT (Orange) Antifreeze/Coolant 50/50 mix with distilled water.

Transmission Fluid Manual:

NV3550: Mopar Manual Transmission Lubricant (or equivalent SAE 75W-90 synthetic gear oil).

Transmission Fluid Automatic:

42RLE: ATF+4 (Automatic Transmission Fluid) - Mopar P/N 05013457AA.

Differential Fluid:

SAE 80W-90 Hypoid Gear Lubricant (API GL-5). For limited-slip differentials, use SAE 80W-90 with friction modifier.

Power Steering Fluid:

ATF+3 or ATF+4

Known Issues

Common Wear Item:

Clutch wear (manual transmission), rear main seal leaks.

Suspension Components:

Worn control arm bushings, track bar bushings, and sway bar links due to off-road use or age.

Steering Components:

Worn steering stabilizer, loose steering box, worn tie rod ends.

Rust:

Corrosion on frame, rocker panels, and body mounts is a common concern, especially in areas with road salt.

Electrical Gremlins:

Intermittent electrical issues can arise due to age, corrosion in connectors, and aftermarket modifications.

Cooling System:

Radiator leaks, thermostat issues, and water pump failures can occur.

Transfer Case Chain:

Stretching of the transfer case chain in the NP231 can lead to driveability issues.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Direct descendant of the Willys MB WWII Jeep, emphasizing ruggedness, utility, and off-road prowess.

Model Evolution

Tj Generation Introduction:

Introduced for the 1997 model year as a replacement for the YJ Wrangler, featuring a coil-spring suspension for improved ride comfort and articulation.

Tj Generation Design:

Return to round headlights (a departure from the YJ's square headlights), modern interior amenities, and improved safety features.

Tj 2002 Updates:

Minor updates typically include revised trim packages, exterior color options, and potential interior material changes. No major mechanical overhauls for this year.

Production

Production Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Offroad Magazine Awards:

Consistently rated highly by off-road publications for its capabilities and aftermarket support.

Ratings

Consumer Satisfaction:

Generally positive consumer satisfaction, particularly among enthusiasts who value its off-road prowess and customization potential.