🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Platform Code: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle. Competitive Analysis Competitors: Ford Bronco, Toyota 4Runner, Suzuki Samurai (at the time of its generation). Key Features Off Road Capability: Renowned for its rugged body-on-frame construction, solid axles, and short wheelbase, making it highly capable off-road. Iconic Design: Classic Jeep design with round headlights, seven-slot grille, and removable doors/top. Manual Purpose Target Audience: Professional automotive technicians and advanced DIY enthusiasts. 📋 Manual Details Coverage Areas Primary Coverage: All mechanical, electrical, and body systems for the 2002 Jeep Wrangler TJ. Page Count Estimated Pages: Over 2000 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: 4.0L Power Tech I6 (2002 model year specific tuning, diagnostics, component repair). Transmission: NV3550 5-Speed Manual, 42RLE 4-Speed Automatic (disassembly, assembly, diagnostics, repair, fluid specifications). Drivetrain: NP231 Command-Trac Transfer Case, Dana 30 (front axle), Dana 35c (rear axle) specifications, maintenance, and repair procedures. Suspension Steering: Front coil spring solid axle, rear coil spring solid axle, steering system (gearbox, linkage), alignment specifications. Brakes: Front disc, rear drum braking system (component identification, overhaul, bleeding, ABS diagnostics if equipped). Electrical: Complete wiring diagrams, fuse box layouts, starter, alternator, battery, lighting, instrumentation, body control module (BCM) if applicable, diagnostic trouble codes (DTCs) and troubleshooting. Body: Body panel removal/installation, interior trim, soft top and hardtop service, doors, hood, tailgate, exterior trim. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling. Procedures Included Maintenance: Routine maintenance tasks: oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic flowcharts for common drivability, electrical, and mechanical issues. Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major systems. Diagnostics: Detailed diagnostic procedures, including symptom-based troubleshooting and use of scan tools. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIYers. Covers complete engine rebuilds, transmission overhauls, electrical system diagnostics, and chassis repairs. 📊 Manual Specifications File Format File Type: PDF Print Quality Resolution: High-resolution scans, ensuring clarity of text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-Cylinder, SOHC Engine Code: AMC 242 / Power Tech I6 Performance Displacement: 4.0 Liters (242 cubic inches) Horsepower Gross: 190 hp @ 4600 rpm (approx.) Torque Gross: 235 lb-ft @ 3200 rpm (approx.) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI). Recommended Fuel: 87 Octane Unleaded Gasoline. Engine Management ECU Type: Chrysler's DRB-III diagnostic system (referenced in manual for troubleshooting). 🔧 Transmission Standard Manual Transmission: NV3550 5-Speed Manual Optional Automatic Transmission: 42RLE 4-Speed Automatic Features Transfer Case: NP231 Command-Trac (Part-time, 2WD, 4WD High, 4WD Low). Fluid Specifications Manual Trans Fluid: API GL-3 or GL-4 SAE 75W-90 Synthetic Gear Lubricant (specific brands and quantities detailed in manual). Automatic Trans Fluid: ATF+4 (MS-9602) (specific brands and quantities detailed in manual). Transfer Case Fluid: Mopar NV231 Spec or equivalent ATF+4 (specific brands and quantities detailed in manual). 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Overall Length: 150.0 inches (3810 mm) Overall Width: 66.7 inches (1694 mm) Overall Height: 71.5 inches (1816 mm) (with hardtop) Weights Curb Weight: Approx. 3,200 - 3,500 lbs (depending on configuration) Gross Vehicle Weight Rating: Approx. 4,500 - 4,800 lbs 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star (as per typical NHTSA ratings for this era, specific to 2002 may vary slightly) Active Features ABS: Available (standard on some trims, optional on others). Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point front seatbelts, lap belts in rear (depending on configuration). 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional premium sound system. Speaker configurations vary by trim. Driver Assistance Cruise Control: Available on most models. Connectivity Phone Integration: Not typically equipped with factory Bluetooth or smartphone integration; aftermarket solutions common. 🔧 Maintenance Service Intervals Oil Change: Every 3,000 miles or 3 months, whichever comes first (severe duty/off-road recommended). Air Filter: Inspect every 15,000 miles, replace as needed. Spark Plugs: Replace every 60,000 - 100,000 miles (depending on plug type, refer to manual for exact spec). Coolant Flush: Every 30,000 miles or 2 years. Fluid Specifications Engine Oil: SAE 10W-30 API SJ or higher (e.g., Mopar SAE 10W-30). Coolant: Chrysler OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) type coolant, typically dark green or orange (e.g., Mopar 5 Year Coolant). Brake Fluid: DOT 3 or DOT 4 (Refer to specific cap on reservoir). Known Issues Common Problems: Rear main seal leaks, radiator leaks, exhaust manifold cracks (especially on 4.0L), death wobble (steering stabilizer and component wear), clutch wear (manual transmission). Common Problems Electrical: Alternator failures, wiring harness chafing (especially...