2002 Jeep Wrangler Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact SUV / Off-road vehicle Target Audience: Jeep Wrangler owners seeking to perform their own maintenance and repairs, DIY enthusiasts, independent repair shops. Competitive Analysis Competitors: Toyota Tacoma (though truck focus), Suzuki Samurai (older), Ford Bronco (older), Land Rover Defender (older/different market). Key Features Offroad Capability: Renowned for its off-road prowess, solid axles (on most trims), short wheelbase, and approach/departure angles. Simplicity Reliability: Generally considered a robust and mechanically simple vehicle, making it a favorite for modification and long-term ownership. Iconic Design: Timeless design characterized by the seven-slot grille, round headlights, and exposed door hinges. 📋 Manual Details Coverage Areas Engine Coverage: 4.0L Inline-6 (e.g., AMC 242), 2.4L Inline-4 (e.g., PowerTech) Transmission Coverage: 4-Speed Automatic (42RLE), 5-Speed Manual (NV3550) Drivetrain Coverage: 2WD and 4WD (Command-Trac, Selec-Trac - if applicable) Body Style Coverage: 2-Door Sport/Sahara/Rubicon Page Count Estimated Pages: ~1500-2000 (Software often dynamically displays relevant sections) Manual Type Type: Service and Repair Manual Software Language Language: English Format Format: Digital Software (likely executable or PDF-based) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, pistons, crankshaft, camshaft, timing, lubrication system, cooling system, fuel delivery, exhaust system, emissions controls Engine Electrical: Ignition system, starting system, charging system, fuel injection system (PCM, sensors, actuators), engine diagnostics Transmission Manual: NV3550: Disassembly, inspection, assembly, shift linkage, clutch system, hydraulic components Transmission Automatic: 42RLE: Component identification, hydraulic control, torque converter, valve body, cooling, electronic controls Drivetrain: Transfer case (NP231J Command-Trac, potentially NP241OR for Rubicon): Removal, disassembly, inspection, repair; Front and rear axles (Dana 30/35/44 - depending on trim): Disassembly, inspection, bearing replacement, seal replacement, differential adjustment Suspension: Front and rear coil springs, shock absorbers, control arms, sway bars, bushings, steering knuckles, alignment specifications Steering: Steering gear (steering box), power steering pump, power steering hoses, tie rods, steering linkage, steering column, alignment Brakes: Front disc brakes, rear drum or disc brakes (depending on model/trim), hydraulic system (master cylinder, brake lines, calipers/wheel cylinders, brake booster), parking brake system, ABS system (if equipped) Electrical System: Battery, starter, alternator, ignition, lighting (headlights, taillights, interior), horns, wipers, power windows/locks (if equipped), wiring diagrams, fuse/relay identification and function Body And Frame: Frame inspection and repair, body panel removal/installation, doors, hood, tailgate, fenders, bumpers, convertible top service, interior trim, seats HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant recharge), heater core, blower motor, controls, ducting Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), tire rotations, spark plug replacement Diagnostics Troubleshooting: Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting guides, component testing procedures Repair Rebuild: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Torque Specifications: Accurate torque values for critical fasteners (e.g., cylinder head bolts, main bearing caps, suspension components, wheel lug nuts). Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, including power distribution, component location, and circuit tracing. Technical Depth Depth: Comprehensive coverage from basic maintenance to complex engine and transmission overhauls. Includes diagnostic procedures and specifications required for professional-level repairs. 📊 Manual Specifications File Format Compatibility: Designed to run on Windows operating systems (verify specific version requirements if possible). Print Quality Output Quality: Printable sections with high-resolution diagrams and clear text. Binding Type Binding: N/A (Software format) Paper Type Paper Type: N/A (Software format) ⚙️ Engine Specifications Primary Engine Engine 1 Name: 4.0L Inline-6 (AMC 242) Engine 1 Displacement: 3957 cc (242 ci) Engine 1 Horsepower: 190 hp @ 4600 rpm Engine 1 Torque: 235 lb-ft @ 3200 rpm Engine 1 Bore X Stroke: 3.875 in x 3.56 in (98.4 mm x 90.5 mm) Engine 1 Compression Ratio: 8.8:1 Engine 1 Fuel Delivery: Sequential Multi-Port Fuel Injection (MPFI) Engine 1 Firing Order: 1-5-3-6-2-4 Secondary Engine Engine 2 Name: 2.4L Inline-4 (PowerTech) Engine 2 Displacement: 2429 cc (148 ci) Engine 2 Horsepower: 147 hp @ 5200 rpm Engine 2 Torque: 170 lb-ft @ 3800 rpm Engine 2 Fuel Delivery: Sequential Multi-Port Fuel Injection (MPFI) 🔧 Transmission Standard Transmission Standard Transmission Type: 5-Speed Manual (New Venture Gear NV3550) Optional Transmission Optional Transmission Type: 4-Speed Automatic (42RLE) Features Clutch Type: Hydraulically actuated, single dry plate Transfer Case Standard: NP231J Command-Trac (Part-time, 2WD High, 4WD High, 4WD Low) Transfer Case Rubicon: NP241OR/OR-EX (Rock-Trac) with 4.0:1 low range (standard on Rubicon) 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 156.5 inches (3975 mm) Width: 66.5 inches (1689 mm) Height: 70.4 inches (1788 mm) Ground Clearance: Approximately 8.5-10.5 inches (depending on tires/suspension) Weights Curb Weight: ~3,200 - 3,500 lbs (1450 - 1590 kg) depending on configuration Max Payload: Approximately 800-1000 lbs (360-450 kg) Towing Capacity: 2000 lbs (907 kg) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star rating (typical for this era and vehicle type) Active Features ABS: Optional...

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Sku: 331199

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Tags: 2002 Car Cars Jeep Misc Wrangler

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Description

🏷️ Basic Information

Identification

Make:

Model:

Wrangler

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV / Off-road vehicle

Target Audience:

Jeep Wrangler owners seeking to perform their own maintenance and repairs, DIY enthusiasts, independent repair shops.

Competitive Analysis

Competitors:

Toyota Tacoma (though truck focus), Suzuki Samurai (older), Ford Bronco (older), Land Rover Defender (older/different market).

Key Features

Offroad Capability:

Renowned for its off-road prowess, solid axles (on most trims), short wheelbase, and approach/departure angles.

Simplicity Reliability:

Generally considered a robust and mechanically simple vehicle, making it a favorite for modification and long-term ownership.

Iconic Design:

Timeless design characterized by the seven-slot grille, round headlights, and exposed door hinges.

📋 Manual Details

Coverage Areas

Engine Coverage:

4.0L Inline-6 (e.g., AMC 242), 2.4L Inline-4 (e.g., PowerTech)

Transmission Coverage:

4-Speed Automatic (42RLE), 5-Speed Manual (NV3550)

Drivetrain Coverage:

2WD and 4WD (Command-Trac, Selec-Trac - if applicable)

Body Style Coverage:

2-Door Sport/Sahara/Rubicon

Page Count

Estimated Pages:

~1500-2000 (Software often dynamically displays relevant sections)

Manual Type

Type:

Service and Repair Manual Software

Language

Language:

English

Format

Format:

Digital Software (likely executable or PDF-based)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine removal/installation, cylinder head, pistons, crankshaft, camshaft, timing, lubrication system, cooling system, fuel delivery, exhaust system, emissions controls

Engine Electrical:

Ignition system, starting system, charging system, fuel injection system (PCM, sensors, actuators), engine diagnostics

Transmission Manual:

NV3550: Disassembly, inspection, assembly, shift linkage, clutch system, hydraulic components

Transmission Automatic:

42RLE: Component identification, hydraulic control, torque converter, valve body, cooling, electronic controls

Drivetrain:

Transfer case (NP231J Command-Trac, potentially NP241OR for Rubicon): Removal, disassembly, inspection, repair; Front and rear axles (Dana 30/35/44 - depending on trim): Disassembly, inspection, bearing replacement, seal replacement, differential adjustment

Suspension:

Front and rear coil springs, shock absorbers, control arms, sway bars, bushings, steering knuckles, alignment specifications

Steering:

Steering gear (steering box), power steering pump, power steering hoses, tie rods, steering linkage, steering column, alignment

Brakes:

Front disc brakes, rear drum or disc brakes (depending on model/trim), hydraulic system (master cylinder, brake lines, calipers/wheel cylinders, brake booster), parking brake system, ABS system (if equipped)

Electrical System:

Battery, starter, alternator, ignition, lighting (headlights, taillights, interior), horns, wipers, power windows/locks (if equipped), wiring diagrams, fuse/relay identification and function

Body And Frame:

Frame inspection and repair, body panel removal/installation, doors, hood, tailgate, fenders, bumpers, convertible top service, interior trim, seats

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant recharge), heater core, blower motor, controls, ducting

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), tire rotations, spark plug replacement

Diagnostics Troubleshooting:

Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting guides, component testing procedures

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Torque Specifications:

Accurate torque values for critical fasteners (e.g., cylinder head bolts, main bearing caps, suspension components, wheel lug nuts).

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, including power distribution, component location, and circuit tracing.

Technical Depth

Depth:

Comprehensive coverage from basic maintenance to complex engine and transmission overhauls. Includes diagnostic procedures and specifications required for professional-level repairs.

📊 Manual Specifications

File Format

Compatibility:

Designed to run on Windows operating systems (verify specific version requirements if possible).

Print Quality

Output Quality:

Printable sections with high-resolution diagrams and clear text.

Binding Type

Binding:

N/A (Software format)

Paper Type

Paper Type:

N/A (Software format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Name:

4.0L Inline-6 (AMC 242)

Engine 1 Displacement:

3957 cc (242 ci)

Engine 1 Horsepower:

190 hp @ 4600 rpm

Engine 1 Torque:

235 lb-ft @ 3200 rpm

Engine 1 Bore X Stroke:

3.875 in x 3.56 in (98.4 mm x 90.5 mm)

Engine 1 Compression Ratio:

8.8:1

Engine 1 Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPFI)

Engine 1 Firing Order:

1-5-3-6-2-4

Secondary Engine

Engine 2 Name:

2.4L Inline-4 (PowerTech)

Engine 2 Displacement:

2429 cc (148 ci)

Engine 2 Horsepower:

147 hp @ 5200 rpm

Engine 2 Torque:

170 lb-ft @ 3800 rpm

Engine 2 Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPFI)

🔧 Transmission

Standard Transmission

Standard Transmission Type:

5-Speed Manual (New Venture Gear NV3550)

Optional Transmission

Optional Transmission Type:

4-Speed Automatic (42RLE)

Features

Clutch Type:

Hydraulically actuated, single dry plate

Transfer Case Standard:

NP231J Command-Trac (Part-time, 2WD High, 4WD High, 4WD Low)

Transfer Case Rubicon:

NP241OR/OR-EX (Rock-Trac) with 4.0:1 low range (standard on Rubicon)

📐 Dimensions

Exterior

Wheelbase:

93.4 inches (2372 mm)

Length:

156.5 inches (3975 mm)

Width:

66.5 inches (1689 mm)

Height:

70.4 inches (1788 mm)

Ground Clearance:

Approximately 8.5-10.5 inches (depending on tires/suspension)

Weights

Curb Weight:

~3,200 - 3,500 lbs (1450 - 1590 kg) depending on configuration

Max Payload:

Approximately 800-1000 lbs (360-450 kg)

Towing Capacity:

2000 lbs (907 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star rating (typical for this era and vehicle type)

Active Features

Optional Anti-lock Braking System (ABS) on rear wheels or all four wheels depending on trim and options.

Passive Features

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point front seatbelts with pretensioners, lap belts for rear passengers.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player (optional), cassette player (optional). Basic speaker configurations.

Driver Assistance

Cruise Control:

Available cruise control system.

Connectivity

Auxiliary Inputs:

Typically limited to factory options, no standard USB or Bluetooth connectivity in this era.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 3,000-5,000 miles or 6 months, whichever comes first (depending on driving conditions and oil type used).

Coolant Change Interval:

Every 30,000 miles or 2 years.

Transmission Fluid Change Automatic:

Every 30,000-60,000 miles (refer to manual for severe service).

Transmission Fluid Change Manual:

Every 50,000-100,000 miles (refer to manual).

Differential Fluid Change:

Every 30,000-50,000 miles, especially if used for off-roading or towing.

Spark Plug Replacement:

4.0L: Typically 100,000 miles (platinum/iridium plugs). 2.4L: Refer to manual, potentially 30,000-60,000 miles.

Fluid Specifications

Engine Oil Type:

SAE 10W-30 (preferred for 4.0L), consult manual for specific API service classification.

Coolant Type:

Chrysler OAT (Organic Acid Technology) Antifreeze/Coolant, typically orange or red.

Automatic Transmission Fluid:

ATF+4 (Chrysler Automatic Transmission Fluid Type 9602)

Manual Transmission Fluid:

NV3550 requires specialized manual transmission fluid, often synthetic 75W-90 or specified by Mopar.

Power Steering Fluid:

Power steering fluid or ATF+3/ATF+4 (check manual for exact specification).

Brake Fluid Type:

DOT 3

Known Issues

Cracked Cylinder Heads:

The 4.0L engine is known for susceptibility to cracked cylinder heads, especially with overheating or coolant loss. Early detection and proper maintenance are crucial.

Death Wobble:

A phenomenon involving severe front-end shimmy or vibration at certain speeds, often caused by worn steering or suspension components (e.g., track bar, ball joints, tie rods, steering stabilizer).

Oil Filter Adapter Leak:

Leaking oil filter adapter seals can cause oil to seep onto the exhaust manifold, creating smoke and a fire hazard.

Heater Core Leaks:

Heater cores can fail, leading to coolant leaks inside the cabin and fogged windows.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Continuation of Jeep's long lineage of rugged, go-anywhere vehicles originating from WWII Willys MB.

Model Evolution

Tj Generation:

The TJ generation (1997-2006) marked a significant departure from the YJ by returning to coil springs and eliminating the leaf springs, improving ride comfort and articulation.

Rubicon Introduction:

The 2003 model year introduced the Rubicon trim, featuring Dana 44 axles front and rear, locking differentials, a disconnecting front sway bar, and a lower transfer case ratio for enhanced off-road capability.

Production

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Offroad Awards:

Consistently praised by off-road publications and enthusiasts for its capability and aftermarket support.

Ratings

Consumer Reports:

Variable reliability ratings over the years, often dependent on specific components and maintenance. Strong owner satisfaction for off-road use.