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2002 Jeep Wrangler TJ Service Repair Manual
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Basic Information Identification Make: Jeep Model: Wrangler Model Code: TJ Year: 2002 Generation Generation Code: TJ Generation Years: 1997-2006 Introduction Market Position Vehicle Segment: Compact/Mid-size SUV, Off-road focused Jeep Brand...
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| Basic Information | |
| Identification | |
| Make: | Jeep |
| Model: | Wrangler |
| Model Code: | TJ |
| Year: | 2002 |
| Generation | |
| Generation Code: | TJ |
| Generation Years: | 1997-2006 |
| Introduction | |
| Market Position | |
| Vehicle Segment: | Compact/Mid-size SUV, Off-road focused |
| Jeep Brand Heritage: | Renowned for ruggedness, off-road capability, and open-air driving experience |
| Competitive Analysis | |
| Direct Competitors: | Suzuki Samurai (earlier models), Toyota FJ Cruiser (later models), Land Rover Defender (historically) |
| Key Features | |
| Iconic Design: | Solid front axle, iconic 7-slot grille, removable doors and top |
| Off Road Capability: | Known for excellent articulation, ground clearance, and robust 4x4 systems |
| Manual Details | |
| Coverage Areas | |
| Manual Type: | Factory Service Repair Manual |
| Language: | English |
| Format: | Digital (likely PDF) |
| Page Count | |
| Estimated Page Count: | 1500+ |
| Manual Type | |
| Manual Purpose: | Do-it-yourself (DIY) and professional technician use |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Yes (diagnosis, repair, specifications) |
| Transmission: | Yes (manual and automatic diagnosis, repair, specifications) |
| Drivetrain: | Yes (4WD system, transfer case, axles, driveshafts) |
| Suspension: | Yes (front and rear, components, alignment) |
| Steering: | Yes (power steering system, components, diagnosis) |
| Brakes: | Yes (front and rear disc, ABS if equipped, hydraulic system) |
| Electrical: | Yes (charging system, starting system, lighting, instrumentation, wiring diagrams) |
| Body: | Yes (exterior panels, doors, interior trim, convertible top) |
| HVAC: | Yes (heating, ventilation, air conditioning system) |
| Fuel: | Yes (fuel tank, pump, lines, injection system) |
| Cooling: | Yes (radiator, water pump, thermostat, hoses) |
| Exhaust: | Yes (components, catalytic converter) |
| Emissions: | Yes (emission control systems, diagnosis) |
| Procedures Included | |
| Maintenance: | Yes (scheduled maintenance, fluid changes, filter replacements) |
| Troubleshooting: | Yes (diagnostic charts, symptom-based diagnosis) |
| Repair: | Yes (component removal, installation, adjustment, overhaul) |
| Diagnostics: | Yes (OBD-II system, sensor testing, actuator testing) |
| Specifications: | Yes (torque values, clearances, fluid capacities, electrical values) |
| Technical Depth | |
| Depth: | Comprehensive (from basic fluid changes to full engine/transmission rebuilds) |
| Diagrams: | High-quality, detailed diagrams and illustrations |
| Wiring Diagrams: | Detailed electrical system wiring diagrams |
| Manual Specifications | |
| File Format | |
| Digital Format: | Likely PDF, often searchable and printable |
| Print Quality | |
| Text Quality: | Easy-to-read text sections |
| Diagram Quality: | Top quality diagrams |
| Binding Type | |
| Physical Manual Binding: | If printed, typically coil-bound or perfect-bound for lay-flat use |
| Paper Type | |
| Physical Manual Paper: | If printed, durable, high-quality paper suitable for shop environments |
| Engine Specifications | |
| Primary Engine | |
| Engine Code: | 4.0L Inline-6 (PowerTech) |
| Engine Displacement Liters: | 4.0 |
| Engine Displacement Ci: | 242 |
| Engine Configuration: | Inline 6-cylinder |
| Valve Train: | Overhead Valve (OHV) |
| Bore X Stroke: | 3.875 in x 3.560 in (98.4 mm x 90.5 mm) |
| Compression Ratio: | 8.8:1 |
| Performance | |
| Horsepower Hp: | 190 @ 4450 RPM |
| Torque Lb-Ft: | 235 @ 3200 RPM |
| Fuel System | |
| Fuel Delivery: | Electronic Multi-Point Fuel Injection (MPI) |
| Recommended Fuel: | 87 Octane Unleaded Gasoline |
| Cooling | |
| Coolant Capacity Quarts: | 10.0 |
| Coolant Type: | Chrysler/Mopar HOAT Antifreeze/Coolant (50/50 mix with distilled water) |
| Oil Capacity Quarts | |
| Engine Oil Capacity Quarts: | 6.0 (with filter) |
| Oil Specifications | |
| Engine Oil Viscosity: | SAE 10W-30 |
| Engine Oil Specification: | API SJ or SL, ILSAC GF-3 |
| Transmission | |
| Standard | |
| Transmission Type Std: | NV3550 5-Speed Manual |
| Optional | |
| Transmission Type Opt: | 42RLE 4-Speed Automatic |
| Features | |
| Manual Transmission Fluid Spec: | Dexron III/Mercon ATF (check manual for specific NV3550 fluid) |
| Automatic Transmission Fluid Spec: | ATF+4 (Chrysler Mopar) |
| Transfer Case Type: | NV241 GII (Command-Trac part-time 2-speed transfer case) |
| Transfer Case Fluid Spec: | ATF+4 (Chrysler Mopar) or equivalent |
| Dimensions | |
| Exterior | |
| Wheelbase Inches: | 93.4 |
| Overall Length Inches: | 151.4 |
| Overall Width Inches: | 66.7 |
| Overall Height Inches: | 70.0 (with soft top) |
| Ground Clearance Inches: | 10.1 (approx.) |
| Weights | |
| Curb Weight Lbs: | 3277 - 3423 (depending on configuration) |
| Gross Vehicle Weight Rating Gvwr Lbs: | 4600 |
| Wheels Tires | |
| Standard Tire Size: | P215/75R15 or LT215/75R15 |
| Optional Tire Size: | LT225/75R16 |
| Wheel Bolt Pattern: | 5x114.3mm (5x4.5 inches) |
| Wheel Size: | 15x7 or 16x7 |
| Safety Features | |
| Ratings | |
| NHTSA Front Crash Test Rating: | Four-star driver, Four-star passenger (for the 2002 model year) |
| IIHS Side Impact Rating: | Good |
| Active Features | |
| ABS: | Optional on 2002 models (typically 4-wheel disc with ABS) |
| Passive Features | |
| Airbags: | Driver and passenger front airbags |
| Seat Belts: | 3-point front seat belts, rear lap belts |
| Construction | |
| Body On Frame: | Yes, robust body-on-frame construction |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory AM/FM/CD player, optional premium sound system |
| Display: | Basic digital display for radio/clock |
| Driver Assistance | |
| Cruise Control: | Available on some trims |
| Connectivity | |
| Auxiliary Input: | Typically not standard, aftermarket solutions common |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval Miles: | 3000-5000 miles (depending on driving conditions and oil type) |
| Tire Rotation Interval Miles: | 6000-7500 miles |
| Coolant Flush Interval Miles: | 30,000 - 50,000 miles or every 2-3 years |
| Transmission Fluid Change Interval Miles: | 30,000 - 60,000 miles (depending on usage, heavier for towing/off-roading) |
| Fluid Specifications | |
| Brake Fluid Type: | DOT 3 |
| Power Steering Fluid Type: | ATF+4 (Chrysler Mopar) or equivalent |
| Transfer Case Fluid Part Number: | Mopar ATF+4 (05013457AA or equivalent) |
| Known Issues | |
| Common Issues Engine: | Cracking exhaust manifolds, oil filter adapter leaks, occasional head gasket issues (less common on 4.0L compared to some other engines) |
| Common Issues Suspension: | Worn control arm bushings, track bar wear, sway bar link issues, death wobble (especially with tire wear or incorrect alignment) |
| Common Issues Electrical: | Horn not working (clock spring issue), blower motor resistor failure, intermittent gauge problems |
| Common Issues Body: | Rust on the tub, particularly rocker panels and floor pans; door hinge corrosion |
| Vehicle History | |
| Brand Heritage | |
| Jeep Legacy: | Direct descendant of the WWII Willys MB Jeep, a symbol of ruggedness and utility |
| Model Evolution | |
| Tj Introduction: | Introduced in 1997 as a successor to the YJ Wrangler, returning to round headlights and coil springs. |
| Tj Key Changes 2002: | For 2002, the main change was the introduction of the Rubicon trim level, featuring Dana 44 axles, a 4:1 low-range transfer case, and electronically locking front and rear differentials. |
| Production | |
| Manufacturing Location: | Toledo, Ohio, USA |
| Awards & Recognition | |
| Recognitions | |
| Off Road Recognition: | Consistently praised by off-road publications and enthusiasts for its capability. |
| Overall Vehicle Awards: | While not as laden with typical awards as mainstream SUVs, its reputation for durability and off-road prowess is its primary recognition. |