🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Generation: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Positioning: The definitive guide for owners and technicians seeking to maintain, diagnose, and repair the iconic Jeep Wrangler TJ generation. Competitive Analysis Competitors: Other generic online repair guides or simplified owner's manuals lack the depth and specific technical detail of this comprehensive workshop manual. Key Features Value Proposition: Empowers users with factory-level repair information, saving time and money on maintenance and repairs. Target Audience: Jeep Wrangler TJ owners, DIY mechanics, automotive repair shops 📋 Manual Details Coverage Areas Coverage Scope: Complete Workshop Service Repair Page Count Estimated Page Count: 1500-2000 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Transfer Case, Drivetrain Chassis: Suspension (Front & Rear), Steering, Brakes, Frame Electrical: Wiring Diagrams, Lighting, Instrumentation, Power Distribution, Ignition, Charging Body: Body Panels, Doors, Seats, Trim, HVAC Cooling System: Radiator, thermostat, water pump, fan clutch, coolant hoses, heater core. Fuel System: Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) system. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors. Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks Repair: Engine Overhaul, Transmission Rebuild, Brake System Repair, Electrical Component Replacement Troubleshooting: Diagnostic Procedures, Fault Code Interpretation, Symptom-Based Troubleshooting Body And Frame: Frame straightening, collision repair procedures, body panel replacement, convertible top service. Diagnostics: Engine performance diagnostics, electrical system troubleshooting, HVAC system diagnostics. Technical Depth Depth: Comprehensive: From basic fluid changes to full engine and transmission rebuilds, including diagnostics and electrical schematics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable Text Print Quality Printable: Printable Pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Content Detail Diagrams Illustrations: Includes detailed diagrams, schematics, and illustrations for all procedures. ⚙️ Engine Specifications Primary Engine Engine Code: 4.0L Inline-6 (OHV) - PowerTech Engine Displacement: 242 cu in (3952 cc) Engine Configuration: Inline 6-Cylinder, Overhead Valve (OHV) 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) Ignition System Ignition Type: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Distributor Ignition (depending on exact build date/spec) Cooling System Thermostat Rating: 195°F (90.5°C) typically 🔧 Transmission Standard Transmission Type: NV3550 5-Speed Manual Transmission Optional Transmission Type: 42RLE 4-Speed Automatic Transmission Features Transfer Case Manual: NV231 HD Command-Trac (Part-time, 2.72:1 low range) Transfer Case Automatic: NP241OR/2410 with Selec-Trac (Full-time 4WD option available) Fluid Specifications Manual Nv3550 Fluid: Mopar Manual Transmission Lubricant (MS-9224) or equivalent (e.g., Castrol Syntrans) Fluid Specifications Automatic 42Rle Fluid: ATF+4 (MS-9602) 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 151.4 inches (3845 mm) Width: 66.5 inches (1689 mm) Height: 71.3 inches (1811 mm) Ground Clearance: 10.2 inches (259 mm) Approach Angle: 47.5 degrees (approx.) Departure Angle: 39.2 degrees (approx.) Breakover Angle: 21.3 degrees (approx.) Weights Curb Weight Manual: ~3460 lbs (~1570 kg) Curb Weight Automatic: ~3530 lbs (~1600 kg) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star Active Features Brakes: Front Disc, Rear Drum (ABS optional/standard on some trims) Passive Features Airbags: Driver and Passenger Frontal Airbags 💡 Technology Features Infotainment Audio System: Basic AM/FM stereo with CD player or cassette player, optional premium sound system. Connectivity: Limited by era; primarily analog systems. Auxiliary inputs not standard. Driver Assistance ABS: Optional on some models, standard on others. Always verify for specific vehicle. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (or 6 months), depending on driving conditions and oil type used. Engine Air Filter: Replace every 15,000-30,000 miles or as needed based on inspections. Spark Plugs: Replace approximately every 100,000 miles for platinum or iridium plugs (check specific plug type). Fluid Specifications Engine Oil Capacity: 6 US quarts (5.7 Liters) with filter, using SAE 10W-30 (check owner's manual for exact spec). Coolant Capacity: Approx. 11 US quarts (10.4 Liters) for 4.0L engine. Brake Fluid: DOT 3 Power Steering Fluid: Mopar Power Steering Fluid or ATF+4 (check manual for specific recommendation) Transfer Case Fluid: NP231/NP241: Mopar NV241 Transfer Case Lubricant (MS-9224) or equivalent. Known Issues Common Problems: Cracking exhaust manifolds (especially on 4.0L), distributor drive gear wear, rear main seal leaks, NP241 transfer case chain stretch, automatic transmission cooler line leaks, interior water leaks. Common Problems Continued: Front axle U-joint wear, front axle seal leaks, sway bar links, steering stabilizer failure. 📚 Vehicle History Brand Heritage Jeep Legacy: The Jeep Wrangler TJ (1997-2006) is the fourth generation of the iconic Jeep Wrangler, directly descended from the original Willys MB WWII Jeep and subsequent CJ models. It marked a significant evolution with the introduction of coil springs, replacing the leaf springs of its predecessors, enhancing ride comfort...