Segment:
Compact SUV / Off-Road Vehicle
Reputation:
Iconic off-road capability, rugged design, open-air experience
Competitors 2002:
Toyota Tacoma (SUV variant), Ford Bronco (earlier models), Suzuki Samurai (earlier models)
Design:
Body-on-frame construction, solid axles (front and rear), removable doors and top
Off Road Systems:
Command-Trac NV242 transfer case (part-time 2WD, 4WD Full-time, 4WD Part-time, 4LO), optional Trac-Lok limited-slip differential
Primary Coverage:
Complete Service and Repair Procedures
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Overhaul
Estimated Pages:
Over 1500 Pages (typical for WSM)
Type:
Workshop Service Manual (WSM)
Format:
Digital Download (PDF)
Engine Management:
Fuel Injection, Ignition, Emission Controls, Diagnostics
Powertrain:
Engine Mechanical, Transmission (Automatic & Manual), Transfer Case, Drivetrain
Chassis:
Suspension (Front & Rear), Steering, Brakes (ABS & Non-ABS), Wheels & Tires
Electrical:
Battery, Charging System, Starting System, Lighting, Instruments, Body Control Modules, Powertrain Control Module (PCM)
Body:
Body Panels, Doors, Seats, Interior Trim, Glass, HVAC System
Diagnostics:
Diagnostic Trouble Codes (DTCs), On-Board Diagnostics (OBD-II), Wiring Diagrams
Routine Maintenance:
Oil Change, Filter Replacements, Fluid Checks, Tune-Ups
Major Repairs:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Service
Troubleshooting:
Systematic Diagnostic Flowcharts for Common and Uncommon Issues
Special Tools:
Identification and Usage of Manufacturer-Specific Tools
Specifications:
Torque Specifications, Clearances, Alignment Data, Electrical Resistances
Depth:
Comprehensive (from basic adjustments to complete component rebuilds)
Diagnostic Level:
Advanced Diagnostics and Troubleshooting with Detailed Schematics
Digital Format:
Searchable PDF, Printable Pages
Quality:
Professional Quality, High Resolution
Physical Format If Applicable:
N/A (Digital Download)
Physical Format If Applicable:
N/A (Digital Download)
Engine Code:
4.0L OHV V6 (High Output)
Engine Displacement:
3956 cc (241 cubic inches)
Engine Configuration:
90-degree V6, Overhead Valve (OHV), 2 valves per cylinder
Bore X Stroke:
98.4 mm x 86.7 mm (3.87 in x 3.41 in)
Horsepower Peak:
190 hp (142 kW) @ 4600 rpm
Torque Peak:
235 lb-ft (319 Nm) @ 3200 rpm
Induction Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Engine Control Unit:
Chrysler/Jeep NGC (Next Generation Controller) family
Type Manual:
NV3550 5-speed Manual Transmission
Type Automatic:
42RLE 4-speed Automatic Transmission
Transfer Case:
NV242 'Selec-Trac' (standard) - 2WD, 4WD Full-Time, 4WD Part-Time, Neutral, 4LO
Fluid Specification Manual
Transmission Fluid Type:
Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4)
Fluid Specification Automatic
Transmission Fluid Type:
Mopar ATF+4 (MS-9602)
Transfer Case Fluid Type:
Mopar NV242 Transfer Case Lubricant (or equivalent MS-9224)
Wheelbase:
93.4 inches (2372 mm)
Length:
150.8 inches (3830 mm)
Width:
66.7 inches (1694 mm)
Height:
71.5 inches (1816 mm) (with soft top)
Ground Clearance:
Approx. 8.5 inches (216 mm)
Approach Angle:
43 degrees
Departure Angle:
35 degrees
Breakover Angle:
25 degrees
Curb Weight Manual:
Approx. 3,300 - 3,600 lbs (1497 - 1633 kg)
Curb Weight Automatic:
Approx. 3,400 - 3,700 lbs (1542 - 1678 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 4,800 - 5,000 lbs (2177 - 2268 kg)
NHTSA Rollover Rating 2002:
3-star (driver side, potential for rollover due to high center of gravity)
ABS:
Optional Anti-lock Braking System (ABS) on rear wheels
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
Three-point front seat belts with pretensioners, lap belts in rear
Frame:
Heavy-duty, reinforced steel frame
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first
Engine Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 30,000 miles (48,000 km)
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 48 months
Transmission Fluid Change Automatic:
Every 45,000 miles (72,000 km) or 36 months
Engine Oil Specification:
SAE 10W-30 API Service SN (or equivalent)
Engine Oil Capacity:
5.0 US quarts (4.7 liters) with filter change
Coolant Specification:
Mopar Antifreeze/Coolant 5-Year/100,000 Mile Formula (or equivalent HOAT)
Coolant Capacity:
Approx. 10.5 US quarts (9.9 liters)
Brake Fluid Specification:
DOT 3
Common Issues:
Leaks (oil pan, valve covers, axle seals), transmission synchro wear (manual), cooling system leaks (radiator, hoses), steering box play, exhaust manifold cracks (less common on 4.0L OHV), interior water intrusion (soft top seals).
Jeep Legacy:
Roots tracing back to WWII Willys MB Jeep, synonymous with off-road prowess
Tj Generation:
Second generation Wrangler, introduced for the 1997 model year, replacing the YJ. Key change was the move to coil springs for improved ride and articulation.
2002 Updates:
Minor trim updates, potential minor feature packaging changes. Core mechanicals largely unchanged from initial TJ introduction.
Production Years Tj:
1997-2006
Manufacturing Plant:
Toledo, Ohio, USA
