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Jeep WRANGLER 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Wrangler Year: 2002 Generation Generation Code: TJ Codes Chassis Code: TJ 👋 Introduction Market Position Segment: Compact, body-on-frame SUV, off-road focused Competitive Analysis Competitors: Land Rover Defender (older generations), Toyota Land Cruiser (older generations), Suzuki Samurai Key Features Off Road Capability: Renowned for its legendary off-road prowess with solid front and rear axles, high ground clearance, and robust four-wheel-drive systems. Convertibility: Removable doors, top, and windshield offer an open-air driving experience. Simplicity And Durability: Known for its rugged construction and relatively simple mechanical design. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Secondary Coverage: Diagnostics, Troubleshooting, Maintenance, Overhaul Page Count Estimated Pages: Thousands (typical for comprehensive factory service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely Digital (PDF) or Printed 📖 Manual Coverage Systems Covered Powertrain: Engine (overhaul, rebuilding, performance), Transmission (removal, installation, in-car servicing), Drivetrain Chassis: Front End Alignment, Suspension, Brakes, Steering Electrical: Complete Wiring Diagrams, Diagnostic Trouble Tree Charts, Computer Diagnostics Body And Comfort: Air Conditioning Service and Capacities, Bodywork Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements Repair: Step-by-step repair procedures for all major components Diagnostics: Troubleshooting and diagnostics, computer diagnostic trouble tree charts Rebuilding: Engine overhaul and rebuilding Technical Depth Depth: Detailed, including illustrations, diagrams, depth illustrations, and technical specifications Accessibility: Suitable for individuals with basic mechanical knowledge 📊 Manual Specifications File Format Digital Format: Likely searchable PDF with bookmarking capabilities Print Quality Print Quality: High-resolution for clear diagrams and illustrations Binding Type Binding Type: Spiral-bound or perfect-bound for printed versions, facilitating lay-flat use Paper Type Paper Type: Durable, high-quality paper suitable for workshop environments (for printed versions) ⚙️ Engine Specifications Primary Engine Engine Code And Type: 4.0L Inline 6-cylinder (I6) OHV, known as the 'Power Tech' engine. Engine Displacement: 3956 cc (241.4 cubic inches) Engine Bore X Stroke: 3.88 in x 3.56 in (98.5 mm x 90.5 mm) Engine Compression Ratio: 8.8:1 Performance Horsepower: 190 hp @ 4,750 rpm (approximate for 4.0L) Torque: 235 lb-ft @ 3,200 rpm (approximate for 4.0L) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Codes Engine Codes: ERH (4.0L) Firing Orders Firing Order: 1-5-3-6-2-4 🔧 Transmission Standard Transmission Type: 6-speed manual transmission (NV3550) Optional Transmission Type: 4-speed automatic transmission (42RLE) Features Transfer Case: Selec-Trac NV242 (full-time 4WD capable) or Command-Trac NV231 (part-time 4WD) Fluid Specifications Manual Transmission Fluid: Mopar Manual Transmission Lubricant (or equivalent meeting MS-9224 specification) Automatic Transmission Fluid: ATF+4 (Chrysler spec MS-9602) 📐 Dimensions Exterior Wheelbase: 93.4 inches (2372 mm) Length: 153.3 inches (3894 mm) Width: 66.7 inches (1694 mm) Height: 71.6 inches (1819 mm) Ground Clearance: 8.5 inches (216 mm) minimum Weights Curb Weight: Approximately 3,200 - 3,500 lbs (1451 - 1588 kg), depending on configuration 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4 out of 5 stars (for 2-door models) Active Features Braking System: Front disc, rear drum brakes (standard); Optional front and rear disc brakes ABS: Anti-lock Braking System (ABS) available, typically on front wheels, optional on rear wheels Passive Features Airbags: Driver and passenger front airbags 💡 Technology Features Infotainment Audio System: Basic AM/FM stereo with CD player, optional premium audio, and Infinity speakers. Driver Assistance None: No significant electronic driver assistance features typical of modern vehicles. Connectivity Connectivity Options: Limited to basic audio inputs, no Bluetooth or USB connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type. Engine Coolant Flush: Every 30,000 miles (48,000 km) or 2 years Transmission Fluid Change: Automatic: Every 30,000-60,000 miles (48,000-96,000 km). Manual: As needed, check for leaks. Fluid Specifications Engine Oil Type: SAE 10W-30 (API certified) Engine Oil Capacity: 6 US quarts (5.7 Liters) with filter Coolant Type: Chrysler (Mopar) HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue Brake Fluid Type: DOT 3 Known Issues Common Wear Items: U-joints, ball joints, track bar bushings, oil filter adapter seal leaks, differential seals. Engine Specific: The 4.0L inline-6 is generally very robust. Potential issues can include rear main seal leaks, oil filter adapter seal leaks, and occasional exhaust manifold cracks on older models. Transmission Specific: Manual transmissions can experience clutch wear. Automatic transmissions (42RLE) can develop internal issues with higher mileage. 📚 Vehicle History Brand Heritage Jeep Legacy: Traces its lineage back to the Willys MB military Jeep of World War II, known for ruggedness and off-road capability. Model Evolution Tj Generation Introduction: The TJ Wrangler generation was introduced for the 1997 model year, marking a significant departure from the YJ generation with the return to round headlights and coil springs for the suspension. Production Production Period: The TJ Wrangler was produced from 1997 to 2006. Manufacturing Location: Toledo, Ohio, USA 🏆 Awards & Recognition Recognitions Off Road Accolades: Consistently ranked among the top...
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Jeep WRANGLER 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Wrangler
Year:
2002
Generation
Generation Code:
TJ
Codes
Chassis Code:
TJ
👋 Introduction
Market Position
Segment:
Compact, body-on-frame SUV, off-road focused
Competitive Analysis
Competitors:
Land Rover Defender (older generations), Toyota Land Cruiser (older generations), Suzuki Samurai
Key Features
Off Road Capability:
Renowned for its legendary off-road prowess with solid front and rear axles, high ground clearance, and robust four-wheel-drive systems.
Convertibility:
Removable doors, top, and windshield offer an open-air driving experience.
Simplicity And Durability:
Known for its rugged construction and relatively simple mechanical design.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive Service and Repair
Secondary Coverage:
Diagnostics, Troubleshooting, Maintenance, Overhaul
Page Count
Estimated Pages:
Thousands (typical for comprehensive factory service manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Likely Digital (PDF) or Printed
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (overhaul, rebuilding, performance), Transmission (removal, installation, in-car servicing), Drivetrain
Chassis:
Front End Alignment, Suspension, Brakes, Steering
Electrical:
Complete Wiring Diagrams, Diagnostic Trouble Tree Charts, Computer Diagnostics
Body And Comfort:
Air Conditioning Service and Capacities, Bodywork
Procedures Included
Maintenance:
Routine maintenance, fluid changes, filter replacements
Repair:
Step-by-step repair procedures for all major components
Diagnostics:
Troubleshooting and diagnostics, computer diagnostic trouble tree charts
Rebuilding:
Engine overhaul and rebuilding
Technical Depth
Depth:
Detailed, including illustrations, diagrams, depth illustrations, and technical specifications
Accessibility:
Suitable for individuals with basic mechanical knowledge
📊 Manual Specifications
File Format
Digital Format:
Likely searchable PDF with bookmarking capabilities
Print Quality
Print Quality:
High-resolution for clear diagrams and illustrations
Binding Type
Binding Type:
Spiral-bound or perfect-bound for printed versions, facilitating lay-flat use
Paper Type
Paper Type:
Durable, high-quality paper suitable for workshop environments (for printed versions)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4.0L Inline 6-cylinder (I6) OHV, known as the 'Power Tech' engine.
Engine Displacement:
3956 cc (241.4 cubic inches)
Engine Bore X Stroke:
3.88 in x 3.56 in (98.5 mm x 90.5 mm)
Engine Compression Ratio:
8.8:1
Performance
Horsepower:
190 hp @ 4,750 rpm (approximate for 4.0L)
Torque:
235 lb-ft @ 3,200 rpm (approximate for 4.0L)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Codes
Engine Codes:
ERH (4.0L)
Firing Orders
Firing Order:
1-5-3-6-2-4
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission (NV3550)
Optional
Transmission Type:
4-speed automatic transmission (42RLE)
Features
Transfer Case:
Selec-Trac NV242 (full-time 4WD capable) or Command-Trac NV231 (part-time 4WD)
Fluid Specifications
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant (or equivalent meeting MS-9224 specification)
Automatic Transmission Fluid:
ATF+4 (Chrysler spec MS-9602)
📐 Dimensions
Exterior
Wheelbase:
93.4 inches (2372 mm)
Length:
153.3 inches (3894 mm)
Width:
66.7 inches (1694 mm)
Height:
71.6 inches (1819 mm)
Ground Clearance:
8.5 inches (216 mm) minimum
Weights
Curb Weight:
Approximately 3,200 - 3,500 lbs (1451 - 1588 kg), depending on configuration
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4 out of 5 stars (for 2-door models)
Active Features
Braking System:
Front disc, rear drum brakes (standard); Optional front and rear disc brakes
ABS:
Anti-lock Braking System (ABS) available, typically on front wheels, optional on rear wheels
Passive Features
Airbags:
Driver and passenger front airbags
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo with CD player, optional premium audio, and Infinity speakers.
Driver Assistance
None:
No significant electronic driver assistance features typical of modern vehicles.
Connectivity
Connectivity Options:
Limited to basic audio inputs, no Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type.
Engine Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years
Transmission Fluid Change:
Automatic: Every 30,000-60,000 miles (48,000-96,000 km). Manual: As needed, check for leaks.
Fluid Specifications
Engine Oil Type:
SAE 10W-30 (API certified)
Engine Oil Capacity:
6 US quarts (5.7 Liters) with filter
Coolant Type:
Chrysler (Mopar) HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue
Brake Fluid Type:
DOT 3
Known Issues
Common Wear Items:
U-joints, ball joints, track bar bushings, oil filter adapter seal leaks, differential seals.
Engine Specific:
The 4.0L inline-6 is generally very robust. Potential issues can include rear main seal leaks, oil filter adapter seal leaks, and occasional exhaust manifold cracks on older models.
Transmission Specific:
Manual transmissions can experience clutch wear. Automatic transmissions (42RLE) can develop internal issues with higher mileage.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Traces its lineage back to the Willys MB military Jeep of World War II, known for ruggedness and off-road capability.
Model Evolution
Tj Generation Introduction:
The TJ Wrangler generation was introduced for the 1997 model year, marking a significant departure from the YJ generation with the return to round headlights and coil springs for the suspension.
Production
Production Period:
The TJ Wrangler was produced from 1997 to 2006.
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Accolades:
Consistently ranked among the top off-road vehicles by automotive publications and enthusiast groups.
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