Chrysler Voyager 2002 Workshop Repair Service Manual
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The Chrysler Voyager, produced in 2002, is a capable minivan designed for families and those requiring versatile passenger and cargo space. Built on the RS (North America) or NS platform, this model offered practical solutions for everyday transportation and longer journeys. It was equipped with reliable engine options, including the 3.3L V6 (EGA) and the more powerful 3.8L V6 (L32), paired with efficient 4-speed automatic transmissions like the 41TE and 42LE. Known for its spacious interior and comfortable ride, the Voyager provided a compelling option within its segment, competing with other popular minivans of its era. This comprehensive Workshop Repair Service Manual is your essential guide to understanding, maintaining, and repairing the 2002 Chrysler Voyager. Covering all trims and featuring detailed procedures for both the 3.3L and 3.8L V6 engines, as well as the 41TE and 42LE automatic transmissions, this manual provides in-depth information. It includes routine maintenance schedules, step-by-step repair instructions for all major systems – including engine, transmission, brakes, suspension, steering, and electrical systems – along with troubleshooting guides and diagnostic procedures. This resource is invaluable for owners and technicians alike, ensuring the longevity and optimal performance of your vehicle. 🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Codes Platform Code: NS (for some markets), RS (North America) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, fleet operators, DIY mechanics, professional technicians. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager. Key Features Vehicle Appeal: Spacious interior, comfortable ride, flexible seating arrangements (Stow 'n Go became a significant feature in later iterations of the platform). Manual Value Proposition Utility: Essential resource for maintaining and repairing the Chrysler Voyager 2002, enabling cost savings for owners and providing accurate information for professionals. 📋 Manual Details Coverage Areas Engine Options Covered: 3.3L V6 (EGA), 3.8L V6 (L32) Transmission Options Covered: 41TE (Automatic), 42LE (Automatic) Trim Levels Covered: All trims (e.g., LX, EX, Limited, Stow 'n Go variations may be covered) Market Coverage: Primarily North America, with potential inclusion of international variants (e.g., European Voyager) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging, engine management (PCM/ECU) Transmission Systems: Automatic transmission (41TE/42LE) overhaul, diagnostics, shift control, fluid service Brake Systems: Front and rear brakes (disc/disc), ABS system operation, diagnostic procedures, component replacement Suspension And Steering: Front and rear suspension (struts, control arms, bushings, springs), power steering system, steering gear Electrical Systems: Battery, charging system, starting system, lighting, interior/exterior lights, power windows, locks, mirrors, power sliding door (if equipped), instrument cluster, body control module (BCM), wiring diagrams HVAC Systems: Heating, ventilation, air conditioning (A/C) system operation, diagnostics, refrigerant handling, component replacement Body And Interior: Body panels, doors, hinges, latches, interior trim, seating systems (including Stow 'n Go mechanism if applicable), glass replacement Procedures Included Maintenance Procedures: Routine maintenance (oil changes, filter replacements, spark plugs), inspections, lubrication Repair Procedures: Component removal and installation, rebuilding procedures for major components (engine, transmission), bodywork repairs Troubleshooting Procedures: System-specific diagnostic charts, symptom-based troubleshooting, fault code interpretation (OBD-II) Diagnostic Procedures: Step-by-step diagnostic sequences for electrical and mechanical issues, use of diagnostic tools Technical Depth Depth Of Coverage: Comprehensive: from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and body repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text content, allowing for quick information retrieval. Print Quality Print Quality: Professional; designed for clarity and readability when printed. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: EGA Engine Description 1: 3.3L OHV V6 Displacement 1: 3301 cc (201.5 cubic inches) Bore X Stroke 1: 96.0 mm x 76.0 mm (3.78 in x 2.99 in) Compression Ratio 1: 9.1:1 Horsepower 1: 158 hp @ 4500 rpm (SAE Net) Torque 1: 205 lb-ft @ 3400 rpm (SAE Net) Optional Engine Engine Code 2: L32 Engine Description 2: 3.8L OHV V6 (Supercharged option available on some later models, but less common for 2002 Voyager platform) Displacement 2: 3778 cc (230.5 cubic inches) Bore X Stroke 2: 96.0 mm x 84.0 mm (3.78 in x 3.31 in) Compression Ratio 2: 8.5:1 Horsepower 2: 180 hp @ 4400 rpm (SAE Net) Torque 2: 235 lb-ft @ 3400 rpm (SAE Net) Fuel System Fuel Delivery: Electronic Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended) Engine Management ECU Type: Chrysler's Powertrain Control Module (PCM) 🔧 Transmission Standard Transmission Type Standard: 4-Speed Automatic Transmission Model Standard: 41TE Optional Transmission Type Optional: 4-Speed Automatic Transmission Model Optional: 42LE (for 3.8L engine) Features Transmission Features: Electronically controlled, with overdrive, torque converter lock-up....
The Chrysler Voyager, produced in 2002, is a capable minivan designed for families and those requiring versatile passenger and cargo space. Built on the RS (North America) or NS platform, this model offered practical solutions for everyday transportation and longer journeys. It was equipped with reliable engine options, including the 3.3L V6 (EGA) and the more powerful 3.8L V6 (L32), paired with efficient 4-speed automatic transmissions like the 41TE and 42LE. Known for its spacious interior and comfortable ride, the Voyager provided a compelling option within its segment, competing with other popular minivans of its era.
This comprehensive Workshop Repair Service Manual is your essential guide to understanding, maintaining, and repairing the 2002 Chrysler Voyager. Covering all trims and featuring detailed procedures for both the 3.3L and 3.8L V6 engines, as well as the 41TE and 42LE automatic transmissions, this manual provides in-depth information. It includes routine maintenance schedules, step-by-step repair instructions for all major systems – including engine, transmission, brakes, suspension, steering, and electrical systems – along with troubleshooting guides and diagnostic procedures. This resource is invaluable for owners and technicians alike, ensuring the longevity and optimal performance of your vehicle.
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
2002
Codes
Platform Code:
NS (for some markets), RS (North America)
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Families, fleet operators, DIY mechanics, professional technicians.
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager.
Key Features
Vehicle Appeal:
Spacious interior, comfortable ride, flexible seating arrangements (Stow 'n Go became a significant feature in later iterations of the platform).
Manual Value Proposition
Utility:
Essential resource for maintaining and repairing the Chrysler Voyager 2002, enabling cost savings for owners and providing accurate information for professionals.
📋 Manual Details
Coverage Areas
Engine Options Covered:
3.3L V6 (EGA), 3.8L V6 (L32)
Transmission Options Covered:
41TE (Automatic), 42LE (Automatic)
Trim Levels Covered:
All trims (e.g., LX, EX, Limited, Stow 'n Go variations may be covered)
Market Coverage:
Primarily North America, with potential inclusion of international variants (e.g., European Voyager)
Automatic transmission (41TE/42LE) overhaul, diagnostics, shift control, fluid service
Brake Systems:
Front and rear brakes (disc/disc), ABS system operation, diagnostic procedures, component replacement
Suspension And Steering:
Front and rear suspension (struts, control arms, bushings, springs), power steering system, steering gear
Electrical Systems:
Battery, charging system, starting system, lighting, interior/exterior lights, power windows, locks, mirrors, power sliding door (if equipped), instrument cluster, body control module (BCM), wiring diagrams
HVAC Systems:
Heating, ventilation, air conditioning (A/C) system operation, diagnostics, refrigerant handling, component replacement
Body And Interior:
Body panels, doors, hinges, latches, interior trim, seating systems (including Stow 'n Go mechanism if applicable), glass replacement
Step-by-step diagnostic sequences for electrical and mechanical issues, use of diagnostic tools
Technical Depth
Depth Of Coverage:
Comprehensive: from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and body repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text content, allowing for quick information retrieval.
Print Quality
Print Quality:
Professional; designed for clarity and readability when printed.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA
Engine Description 1:
3.3L OHV V6
Displacement 1:
3301 cc (201.5 cubic inches)
Bore X Stroke 1:
96.0 mm x 76.0 mm (3.78 in x 2.99 in)
Compression Ratio 1:
9.1:1
Horsepower 1:
158 hp @ 4500 rpm (SAE Net)
Torque 1:
205 lb-ft @ 3400 rpm (SAE Net)
Optional Engine
Engine Code 2:
L32
Engine Description 2:
3.8L OHV V6 (Supercharged option available on some later models, but less common for 2002 Voyager platform)
Displacement 2:
3778 cc (230.5 cubic inches)
Bore X Stroke 2:
96.0 mm x 84.0 mm (3.78 in x 3.31 in)
Compression Ratio 2:
8.5:1
Horsepower 2:
180 hp @ 4400 rpm (SAE Net)
Torque 2:
235 lb-ft @ 3400 rpm (SAE Net)
Fuel System
Fuel Delivery:
Electronic Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Engine Management
ECU Type:
Chrysler's Powertrain Control Module (PCM)
🔧 Transmission
Standard
Transmission Type Standard:
4-Speed Automatic
Transmission Model Standard:
41TE
Optional
Transmission Type Optional:
4-Speed Automatic
Transmission Model Optional:
42LE (for 3.8L engine)
Features
Transmission Features:
Electronically controlled, with overdrive, torque converter lock-up.
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.2 inches (3028 mm)
Length:
Approx. 187.5 inches (4763 mm)
Width:
Approx. 76.5 inches (1943 mm)
Height:
Approx. 67.9 inches (1725 mm)
Weights
Curb Weight Min:
Approx. 4100 lbs (1860 kg)
Gross Vehicle Weight Rating Gvw:
Approx. 5750 lbs (2608 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating Driver Passenger:
4 of 5 stars
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Optional on some models.
Passive Features
Airbags Front:
Standard driver and front passenger airbags.
Airbags Side:
Optional side-impact airbags, especially for front occupants.
Seatbelts:
Three-point seatbelts for all occupants, with pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette/CD player, optional Infinity or premium sound systems.
Rear Seat Entertainment:
Optional overhead video monitor and DVD player on some higher trims.
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Optional rear parking assist system on some models.
Connectivity
Power Outlets:
12V auxiliary power outlets located in the cabin.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 3-6 months, depending on driving conditions and oil type used (consult manual for exact recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on inspection.
Spark Plug Replacement:
Typically every 60,000-100,000 miles (96,000-160,000 km) for platinum or iridium plugs (check specific plug type).
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), or per severe service schedule. Consult manual for specific fluid type (ATF+4 is common for Chrysler/Dodge).
Fluid Specifications
Engine Oil Spec:
API Service SG, SH, SJ or higher; SAE 5W-30 is commonly recommended for most climates. Check oil cap and manual.
Engine Oil Capacity:
Approx. 4.5 US quarts (4.3 liters) with filter for 3.3L; Approx. 5.0 US quarts (4.7 liters) with filter for 3.8L.
Coolant Spec:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, extended life, or equivalent.
Transmission Fluid Spec:
Chrysler ATF+4 (Automatic Transmission Fluid Type 9602).
Transmission Fluid Capacity:
Approx. 3.5 US quarts (3.3 liters) for dry fill, around 10-12 US quarts (9.5-11.3 liters) for a complete overhaul/flush.
Known Issues
Common Problems Engine:
Head gasket leaks, intake manifold gasket leaks, camshaft/crankshaft position sensor failures, oil filter adapter leaks, EGR valve issues.
Common Problems Transmission:
Torque converter shudder, solenoid pack failures, premature wear of clutches/bands, potential for overheating if transmission cooler is compromised.
Common Problems Electrical:
Faulty power window motors, HVAC blower motor resistor failures, intermittent dashboard warning lights, issues with the power sliding door mechanism.
Common Problems Suspension Steering:
Worn ball joints, tie rod ends, control arm bushings, and sway bar links leading to clunking noises and poor handling. Power steering pump leaks or noise.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation, later part of DaimlerChrysler.
Model Evolution
Generation:
Second Generation (RS/NS Platform)
Previous Generation Years:
1996-2000
Next Generation Years:
2008 onwards (for Chrysler Town & Country/Dodge Grand Caravan, as the Voyager nameplate was phased out for new generations in NA after 2003/2004, but continued in other markets).