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Chrysler Voyager 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Codes Platform Code: NS/GS (North America/Europe) Engine Code Common: EDZ (3.3L V6 OHV) Engine Code Optional: EGW (3.8L V6 OHV) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, individuals seeking versatile passenger and cargo transport Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager Key Features Versatility: Spacious interior, flexible seating configurations, ample cargo space Powertrain Options: Reliable V6 engines offering a balance of power and efficiency Comfort And Convenience: Focus on passenger comfort, available features like power sliding doors, rear entertainment systems (on higher trims) Value Proposition Benefit To Owner: Empowers owners to perform maintenance and repairs, saving on labor costs and ensuring proper vehicle upkeep. 📋 Manual Details Coverage Areas Countries Covered: North America, Europe (and other markets where the Voyager was sold) Trim Levels Covered: All trim levels (e.g., SE, LX, LXi, ES) Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L, 3.8L), Transmission (41TE/AE Automatic), Drivetrain Chassis: Suspension, Steering, Brakes, Wheels, Tires Electrical: Body Electrical, Powertrain Control Module (PCM), Lighting, HVAC Controls, Instruments and Gauges, Audio System, Power Accessories Body: Body Panels, Doors, Glass, Interior Trim, Seats, Roof Systems (including Stow 'n Go where applicable, though less common for 2002), Exterior Trim HVAC: Air Conditioning, Heating, Ventilation, Climate Control Systems Safety Systems: Airbags, Seat Belts, ABS (Anti-lock Braking System), Traction Control Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tune-ups, belt and hose inspections Diagnostics: Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their meanings Repair: Engine component repair/replacement, transmission overhaul, brake system repair, electrical component repair, bodywork repair Disassembly Assembly: Detailed step-by-step instructions for removing, disassembling, and reassembling major vehicle components and systems Special Tools: Identification and usage of specialized tools required for specific repair procedures Technical Depth Depth: Comprehensive, from basic adjustments to complete engine and transmission rebuilds Diagnostics Level: Advanced diagnostic procedures utilizing scan tools and multimeter testing Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems 📊 Manual Specifications File Format Type: PDF Searchability: Searchable text (typically) Print Quality Quality: High-resolution, suitable for printing Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Displacement: 3.3 Liters (201 cubic inches) Configuration: V6, Overhead Valve (OHV), 2 valves per cylinder Bore X Stroke: 3.44 in x 3.75 in (87.3 mm x 95.2 mm) Compression Ratio: 8.9:1 Horsepower Net Std: 158 hp @ 4600 RPM Torque Net Std: 190 lb-ft @ 3200 RPM Optional Engine Displacement: 3.8 Liters (230 cubic inches) Configuration: V6, Overhead Valve (OHV), 2 valves per cylinder Horsepower Net Std: 180 hp @ 4500 RPM Torque Net Std: 230 lb-ft @ 3200 RPM Fuel System Type: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline, 87 Octane (Minimum) Ignition System Type: Distributorless Ignition System (DIS) Cooling System Type: Pressurized, liquid-cooled 🔧 Transmission Standard Type: 4-Speed Automatic Transaxle (41TE/AE) Gear Ratios 3.3L: Refer to manual for specific ratios (e.g., 1st: 2.80, 2nd: 1.51, 3rd: 1.00, Rev: 2.21) Optional Type: N/A (4-Speed Automatic was standard across all engines for this model year) Features Control: Electronic controls with adaptive shift logic Fluid Specifications Type: Chrysler ATF+4 (MS-9602) Fluid Capacity Capacity Approx: Dry Fill: 8.0 Quarts (7.6 Liters), Refill: 4.5 Quarts (4.3 Liters) 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 196.3 inches (4986 mm) Width: 76.7 inches (1948 mm) Height: 68.7 inches (1745 mm) Interior Seating Capacity: 7-8 Passengers Cargo Cargo Volume Behind 3Rd Row: Approx. 15-20 cu. ft. (depending on configuration) Cargo Volume Max: Approx. 140-150 cu. ft. (with seats removed/folded) Weights Curb Weight Approx: 4100 - 4400 lbs (1860 - 2000 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5700 - 5800 lbs (2585 - 2630 kg) Towing Capacity Max: 3500 lbs (1588 kg) with optional towing package 🛡️ Safety Features Ratings NHTSA Front Impact Driver: ★★★★ (4-Star) NHTSA Front Impact Passenger: ★★★★ (4-Star) NHTSA Side Impact Front Seat: ★★★★ (4-Star) NHTSA Side Impact Rear Seat: ★★★★★ (5-Star) IIHS Rollover Rating: Acceptable Active Features ABS: Standard (4-wheel disc brakes on most trims, front disc/rear drum on some base models) Traction Control: Optional (often tied to ABS) Passive Features Airbags: Driver and front passenger airbags; optional side-impact airbags Seat Belts: 3-point seat belts with pretensioners for front seats, 3-point belts for second and third rows Child Seat Anchors: LATCH (Lower Anchors and Tethers for CHildren) system in second-row seating positions 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player or cassette player. Optional premium Infinity sound system. Rear Entertainment: Optional rear-seat video system with flip-down screen and wireless headphones available on higher trims. Driver Assistance Cruise Control: Standard on most...
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Chrysler Voyager 2002 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
2002
Codes
Platform Code:
NS/GS (North America/Europe)
Engine Code Common:
EDZ (3.3L V6 OHV)
Engine Code Optional:
EGW (3.8L V6 OHV)
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Families, individuals seeking versatile passenger and cargo transport
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager
Key Features
Versatility:
Spacious interior, flexible seating configurations, ample cargo space
Powertrain Options:
Reliable V6 engines offering a balance of power and efficiency
Comfort And Convenience:
Focus on passenger comfort, available features like power sliding doors, rear entertainment systems (on higher trims)
Value Proposition
Benefit To Owner:
Empowers owners to perform maintenance and repairs, saving on labor costs and ensuring proper vehicle upkeep.
📋 Manual Details
Coverage Areas
Countries Covered:
North America, Europe (and other markets where the Voyager was sold)
Trim Levels Covered:
All trim levels (e.g., SE, LX, LXi, ES)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.3L, 3.8L), Transmission (41TE/AE Automatic), Drivetrain
Chassis:
Suspension, Steering, Brakes, Wheels, Tires
Electrical:
Body Electrical, Powertrain Control Module (PCM), Lighting, HVAC Controls, Instruments and Gauges, Audio System, Power Accessories
Body:
Body Panels, Doors, Glass, Interior Trim, Seats, Roof Systems (including Stow 'n Go where applicable, though less common for 2002), Exterior Trim
HVAC:
Air Conditioning, Heating, Ventilation, Climate Control Systems
Safety Systems:
Airbags, Seat Belts, ABS (Anti-lock Braking System), Traction Control
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tune-ups, belt and hose inspections
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their meanings
Repair:
Engine component repair/replacement, transmission overhaul, brake system repair, electrical component repair, bodywork repair
Disassembly Assembly:
Detailed step-by-step instructions for removing, disassembling, and reassembling major vehicle components and systems
Special Tools:
Identification and usage of specialized tools required for specific repair procedures
Technical Depth
Depth:
Comprehensive, from basic adjustments to complete engine and transmission rebuilds
Diagnostics Level:
Advanced diagnostic procedures utilizing scan tools and multimeter testing
Wiring Diagrams:
Detailed electrical wiring schematics for all vehicle systems
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Searchable text (typically)
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Displacement:
3.3 Liters (201 cubic inches)
Configuration:
V6, Overhead Valve (OHV), 2 valves per cylinder
Bore X Stroke:
3.44 in x 3.75 in (87.3 mm x 95.2 mm)
Compression Ratio:
8.9:1
Horsepower Net Std:
158 hp @ 4600 RPM
Torque Net Std:
190 lb-ft @ 3200 RPM
Optional Engine
Displacement:
3.8 Liters (230 cubic inches)
Configuration:
V6, Overhead Valve (OHV), 2 valves per cylinder
Horsepower Net Std:
180 hp @ 4500 RPM
Torque Net Std:
230 lb-ft @ 3200 RPM
Fuel System
Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline, 87 Octane (Minimum)
Ignition System
Type:
Distributorless Ignition System (DIS)
Cooling System
Type:
Pressurized, liquid-cooled
🔧 Transmission
Standard
Type:
4-Speed Automatic Transaxle (41TE/AE)
Gear Ratios 3.3L:
Refer to manual for specific ratios (e.g., 1st: 2.80, 2nd: 1.51, 3rd: 1.00, Rev: 2.21)
Optional
Type:
N/A (4-Speed Automatic was standard across all engines for this model year)
Features
Control:
Electronic controls with adaptive shift logic
Fluid Specifications
Type:
Chrysler ATF+4 (MS-9602)
Fluid Capacity
Capacity Approx:
Dry Fill: 8.0 Quarts (7.6 Liters), Refill: 4.5 Quarts (4.3 Liters)
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
196.3 inches (4986 mm)
Width:
76.7 inches (1948 mm)
Height:
68.7 inches (1745 mm)
Interior
Seating Capacity:
7-8 Passengers
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 15-20 cu. ft. (depending on configuration)
Cargo Volume Max:
Approx. 140-150 cu. ft. (with seats removed/folded)
Weights
Curb Weight Approx:
4100 - 4400 lbs (1860 - 2000 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5700 - 5800 lbs (2585 - 2630 kg)
Towing Capacity Max:
3500 lbs (1588 kg) with optional towing package
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
★★★★ (4-Star)
NHTSA Front Impact Passenger:
★★★★ (4-Star)
NHTSA Side Impact Front Seat:
★★★★ (4-Star)
NHTSA Side Impact Rear Seat:
★★★★★ (5-Star)
IIHS Rollover Rating:
Acceptable
Active Features
ABS:
Standard (4-wheel disc brakes on most trims, front disc/rear drum on some base models)
Traction Control:
Optional (often tied to ABS)
Passive Features
Airbags:
Driver and front passenger airbags; optional side-impact airbags
Seat Belts:
3-point seat belts with pretensioners for front seats, 3-point belts for second and third rows
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system in second-row seating positions
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player or cassette player. Optional premium Infinity sound system.
Rear Entertainment:
Optional rear-seat video system with flip-down screen and wireless headphones available on higher trims.
Driver Assistance
Cruise Control:
Standard on most models
Parking Sensors:
Optional rear parking assist system
Connectivity
Remote Keyless Entry:
Optional
Power Sliding Doors:
Optional on most trims, standard on some higher trims.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations)
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed
Spark Plugs Replacement:
30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., platinum)
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), or more frequently if towing or under severe use
Fluid Specifications
Engine Oil:
SAE 5W-30 (API Service SG or higher)
Coolant:
Chrysler Long Life 50/50 Antifreeze/Coolant (or equivalent HOAT - Hybrid Organic Acid Technology)
Brake Fluid:
DOT 3
Power Steering Fluid:
ATF+4 (MS-9602) or Mopar Power Steering Fluid
Known Issues
Transmission Hard Shifting:
Common issue with the 41TE transmission, often related to solenoid pack or valve body wear. Manual details diagnostic and repair procedures.
Power Door Actuator Failure:
Sliding or liftgate power door actuators can fail. Manual covers diagnosis and replacement.
Ignition Coil Failure:
Individual ignition coils or the coil pack can fail, leading to misfires. Manual provides testing procedures.
Blend Door Actuator HVAC:
HVAC blend door actuators can fail, causing temperature control issues. Manual details access and replacement.
Wheel Bearing Wear:
Front wheel bearings can wear prematurely. Manual covers inspection and replacement procedures.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles)
Minivan Pioneering:
Chrysler is widely credited with inventing the modern minivan segment with the Dodge Caravan/Plymouth Voyager in 1983.
Model Evolution
Generation:
Second Generation (NS) - Introduced for the 1996 model year. The 2001 redesign marked the beginning of the Third Generation (RS).
2002 Updates:
Minor revisions, potential package adjustments. The 2002 model year falls within the RS generation, which featured a more aerodynamic design, improved chassis, and updated powertrains.
Global Variants:
The Chrysler Voyager was the European counterpart to the Dodge Grand Caravan, offering slightly different styling and features for international markets.
Production
Manufacturing Locations:
Windsor Assembly Plant, Windsor, Ontario, Canada
Production Years Relevant:
1996-2007 (NS/RS Generations)
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The Chrysler Minivan platform (including Voyager/Grand Caravan) was frequently recognized by Car and Driver, though specific 2002 awards may vary.
Consumer Reports:
Consumer Reports ratings for reliability and satisfaction varied; the manual is crucial for maintaining a vehicle to achieve optimal performance and longevity.
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