Chrysler Voyager 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Market Segment: Minivan Codes Platform: NS (Second Generation) 👋 Introduction Market Position Vehicle Type: Family Minivan Target Audience: Families seeking versatile, comfortable, and practical transportation Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Vans Key Features Versatility: Spacious interior, flexible seating configurations ( Stow 'n Go functionality not yet available in this generation), ample cargo space Comfort: Smooth ride, comfortable seating, quiet cabin for its class Value Proposition: Offered a strong balance of features, space, and price point within the minivan segment 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Digital (PDF) Page Count Page Count: Approx. 2500+ pages (estimated for comprehensive coverage) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine electrical, fuel system, exhaust system, transmission (automatic), drivetrain components (axles, CV joints) Chassis: Suspension (front and rear), steering system, braking system (hydraulic, ABS), wheels and tires Body And Interior: Body panels, doors, windows, interior trim, seats, HVAC system, power accessories (windows, locks, mirrors), lighting system, wiper system Electrical And Electronics: Wiring diagrams, fuse and relay locations, instrument cluster, battery and charging system, starting system, diagnostic trouble codes (DTCs), infotainment system components (radio, speakers), security system Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical troubleshooting flowcharts Repair: Component removal and installation, internal component repair (e.g., engine, transmission), brake caliper replacement, suspension component replacement, body panel repair Diagnostics: On-Board Diagnostics (OBD-II) system, reading and clearing DTCs, sensor testing, actuator testing Technical Depth Depth: Comprehensive (from basic maintenance to major component overhaul and electrical system diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality Quality: High-resolution digital scans, clear diagrams and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: EGW Engine Type: 3.3L V6 (3296cc) Configuration: SOHC (Single Overhead Camshaft), 12 valves Bore X Stroke: 96.0 mm x 76.9 mm (3.78 in x 3.03 in) Compression Ratio: 9.0:1 Performance Horsepower: 180 hp @ 5200 rpm (approx.) Torque: 205 lb-ft @ 3600 rpm (approx.) Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 Engine Management Engine Control Module: Chrysler SBEC (Single Board Engine Controller) or similar, compatible with OBD-II diagnostics 🔧 Transmission Standard Type: 4-speed automatic overdrive Transmission Model: 41TE (most common) Optional Availability: N/A for 2002 model year, 3.3L V6 exclusively paired with automatic Features Torque Converter: Lock-up torque converter for improved fuel efficiency Fluid Specifications Fluid Type: ATF+4 (Automatic Transmission Fluid, Type 9602) Fluid Capacity Capacity: Approx. 4.0 quarts (3.8 liters) for drain and fill, 11.0 quarts (10.4 liters) total capacity 📐 Dimensions Exterior Length: 193.7 inches (491.9 mm) Width: 72.0 inches (182.9 mm) Height: 67.9 inches (172.5 mm) Wheelbase: 112.1 inches (284.7 mm) Interior Passenger Volume: Approx. 135.5 cu ft Cargo Cargo Volume Behind 3Rd Row: Approx. 20.5 cu ft Cargo Volume With 3Rd Row Folded: Approx. 102.2 cu ft Weights Curb Weight: Approx. 4000-4200 lbs (1814-1905 kg), depending on trim and options Gross Vehicle Weight Rating Gvwr: Approx. 5500 lbs (2495 kg) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-Star (for 2002 models with available side airbags) NHTSA Frontal Impact Passenger: 4-Star (for 2002 models with available side airbags) IIHS Moderate Overlap Frontal Offset: Acceptable (Good ratings began to be more common in later years) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Optional (TCS) Passive Features Airbags Front: Standard dual front airbags Airbags Side: Optional front-seat side airbags Seatbelts: 3-point seatbelts for all seating positions, pretensioners for front seats 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD or Cassette player with optional Infinity speaker system Rear Entertainment: Optional rear-seat entertainment system (VHS player with screen) Driver Assistance Cruise Control: Standard Parking Assist: N/A (Not commonly available for this model year) Connectivity Phone Integration: N/A (No factory Bluetooth or integrated smartphone connectivity) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions (refer to manual for specific recommendations) Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) Spark Plug Replacement: 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), especially under severe service Fluid Specifications Engine Oil Type: SAE 5W-30 (API Service SG, SH, SJ or ILSAC GF-2) Engine Oil Capacity: Approx. 4.5 quarts (4.3 liters) with filter Coolant Type: Chrysler Preferred OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) coolant (e.g., Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula) Coolant Capacity: Approx. 11.0 quarts (10.4 liters) Brake Fluid Type: DOT 3 Known Issues Common...
Comprehensive (from basic maintenance to major component overhaul and electrical system diagnostics)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Print Quality
Quality:
High-resolution digital scans, clear diagrams and illustrations
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EGW
Engine Type:
3.3L V6 (3296cc)
Configuration:
SOHC (Single Overhead Camshaft), 12 valves
Bore X Stroke:
96.0 mm x 76.9 mm (3.78 in x 3.03 in)
Compression Ratio:
9.0:1
Performance
Horsepower:
180 hp @ 5200 rpm (approx.)
Torque:
205 lb-ft @ 3600 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87
Engine Management
Engine Control Module:
Chrysler SBEC (Single Board Engine Controller) or similar, compatible with OBD-II diagnostics
🔧 Transmission
Standard
Type:
4-speed automatic overdrive
Transmission Model:
41TE (most common)
Optional
Availability:
N/A for 2002 model year, 3.3L V6 exclusively paired with automatic
Features
Torque Converter:
Lock-up torque converter for improved fuel efficiency
Fluid Specifications
Fluid Type:
ATF+4 (Automatic Transmission Fluid, Type 9602)
Fluid Capacity
Capacity:
Approx. 4.0 quarts (3.8 liters) for drain and fill, 11.0 quarts (10.4 liters) total capacity
📐 Dimensions
Exterior
Length:
193.7 inches (491.9 mm)
Width:
72.0 inches (182.9 mm)
Height:
67.9 inches (172.5 mm)
Wheelbase:
112.1 inches (284.7 mm)
Interior
Passenger Volume:
Approx. 135.5 cu ft
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.5 cu ft
Cargo Volume With 3Rd Row Folded:
Approx. 102.2 cu ft
Weights
Curb Weight:
Approx. 4000-4200 lbs (1814-1905 kg), depending on trim and options
Gross Vehicle Weight Rating Gvwr:
Approx. 5500 lbs (2495 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-Star (for 2002 models with available side airbags)
NHTSA Frontal Impact Passenger:
4-Star (for 2002 models with available side airbags)
IIHS Moderate Overlap Frontal Offset:
Acceptable (Good ratings began to be more common in later years)
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Optional (TCS)
Passive Features
Airbags Front:
Standard dual front airbags
Airbags Side:
Optional front-seat side airbags
Seatbelts:
3-point seatbelts for all seating positions, pretensioners for front seats
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette player with optional Infinity speaker system
Rear Entertainment:
Optional rear-seat entertainment system (VHS player with screen)
Driver Assistance
Cruise Control:
Standard
Parking Assist:
N/A (Not commonly available for this model year)
Connectivity
Phone Integration:
N/A (No factory Bluetooth or integrated smartphone connectivity)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions (refer to manual for specific recommendations)
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km)
Spark Plug Replacement:
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), especially under severe service
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Service SG, SH, SJ or ILSAC GF-2)
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter
Coolant Type:
Chrysler Preferred OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) coolant (e.g., Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula)
Coolant Capacity:
Approx. 11.0 quarts (10.4 liters)
Brake Fluid Type:
DOT 3
Known Issues
Common Problems:
Interior power accessory failures (window regulators, door locks), HVAC blower motor resistor failure, occasional transmission solenoid issues, intake manifold gasket leaks (less common on V6 than V8 in other Chrysler products), EGR valve clogging.
📚 Vehicle History
Brand Heritage
Manufacturer:
Chrysler Corporation (later DaimlerChrysler)
Model Evolution
Generation:
Second Generation (NS) - Introduced for the 1996 model year. The 2002 model is a refresh of this generation.
Updates For 2002:
Minor styling updates, potential interior refinements, and revised option packages compared to earlier NS models.
Production
Assembly Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA (specific location varied by year and plant capacity)
Production Years:
The NS generation was produced from 1996 to 2000. The 2001 model year saw the introduction of the RS platform (Chrysler Town & Country/Dodge Grand Caravan), while the Voyager nameplate continued on the NS platform for some markets or was phased out depending on region. However, this manual specifically covers the 2002 model, implying continued production or availability of this specific configuration for that year in certain markets, or a broader interpretation of the NS platform's lifecycle for service manual purposes.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Frequently listed on Car and Driver's '10Best Trucks and Vans' lists during its initial production years for its practicality and value.
Ratings
Consumer Reports:
Mixed ratings over its lifecycle; often praised for space and comfort but sometimes criticized for reliability in certain areas.
Certifications
Safety Certifications:
Meets all US Federal Motor Vehicle Safety Standards (FMVSS) applicable for the 2002 model year.