2002 Jeep Wrangler Service and Repair Manual

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Factory-Grade Data

2002 Jeep Wrangler service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • X Sport Utility 2-Door
  • Sport Sport Utility 2-Door
  • Sahara Sport Utility 2-Door
  • SE Sport Utility 2-Door

Engines covered

  • 4.0L 242Cu. In. l6 GAS OHV Naturally Aspirated
  • 2.5L 150Cu. In. l4 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Jeep Wrangler Recalls & Complaints

NHTSA #06E02200013/03/2006Component: SERVICE BRAKES, HYDRAULIC

CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAN

Consequence

LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTAN

Remedy

AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE

NHTSA #04E04100007/06/2004Component: EQUIPMENT

BESTOP AFTERMARKET REAR SHELL ROOF RACKS,MANUFACTURED BETWEEN APRIL 27 AND MAY 20, 2004, DESIGNED FOR USE WITH THE BESTOP HARDTOP MADE FOR THE 1986-1995 AND 1997-2003 JEEP WRANGLER. THE COCKPIT COVE

Consequence

SHOULD THIS OCCUR, THE COCKPIT COULD CAUSE INJURY BY STRIKING PERSONS OUTSIDE THE VEHICLE OR COULD B

Remedy

BESTOP WILL NOTIFY ITS CUSTOMERS AND PROVIDE A REPAIR KIT AND INSTALLATION INSTRUCTIONS FREE OF CHAR

NHTSA #06E01100001/02/2006Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

CERTAIN AFTERMARKET AIRTEX ELECTRIC FUEL PUMPS INSTALLED FOR USE AS REPLACEMENT EQUIPMENT FOR CERTAIN 1997-2004 JEEP WRANGLER; 1997-2001 JEEP CHEROKEE; 1997-2004 JEEP GRAND CHEROKEE; AND 2000-2003 DOD

Consequence

IN THE PRESENCE OF AN IGNITION SOURCE, A FUEL LEAK COULD RESULT IN A FIRE.

Remedy

AIRTEX WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE AFFECTED FUEL PUMPS FREE OF CHARGE. THE RECAL

TSB #11010205

Plate - Planetary

TSB #10229256

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10223525

Malfunction Indicator Lamp (MIL) Illumination. Diagnostic Trouble Codes P0407 ? EGR Sensor B Circuit Low, or P0408 ? EGR Sensor B Circuit High Set

TSB #10221686

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10191460

Valve Body. These may cause over drive cycling.

TSB #10175735

Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are neces

TSB #10175743

Disinfectant Solution Recommended for COVID-19

TSB #10175510

DIPAP Requirements - Addition of Jeep Wrangler (JL/JK) and Jeep Gladiator (JT) Hard Top and Targa Top Panel Replacements - All Dealers (Rev. A)

Showing the 8 most recent of 43 technical service bulletins on file with NHTSA.

20151228Component: STRUCTURE:BODYCrash reportedFire reported1 injured

TAKATA RECALL- DRIVING DOWN A DARK COUNTY ROAD- LOST CONTROL OF VEHICLE AND WENT OFF ROAD AND HIT A TREE- UPON IMPACT THE JEEP BURST INTO FLAMES- THE DRIVER WAS PULLED OUT BECAUSE SHE WAS TRAPPED INSI

20031203Component: AIR BAGSCrash reportedFire reported1 injured

WHILE DRIVING AT 30 MPH, THE VEHICLE WAS INVOLVED IN A HEAD ON COLLISION AND THE AIRBAGS DID NOT DEPLOY. *AK THE VEHICLE CRASHED WITH INTO A LARGE TREE. *SCC *JB

20040309Component: TIRESCrash reported2 injured

FRONT TIRE BLEW OUT, LOST CONTROL OF JEEP AND CRASHED INTO WALL

20040202Component: AIR BAGS:FRONTALCrash reported2 injured

MY AIRBAGS DID NOT DEPLOY WHEN I WAS INVOLVED IN A HEAD ON COLLISION THAT ENDED UP TOTALING MY VEHICLE. *JB

20031120Component: AIR BAGS:FRONTALCrash reported2 injured

WHILE DRIVING APPROXIMATELY 35 MPH, SOMEHOW THE VEHICLE HIT THE REAR OF A SCHOOL BUS. THE FRONT AIR BAGS DID NOT DEPLOY. THE DRIVER'S CHEST HIT THE STEERING WHEEL. THE PASSENGER'S HEAD HIT THE DASH

Showing the 5 most serious of 139 complaints filed with NHTSA.

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