Basic Information Identification Make: Chrysler Model: Grand Voyager Year: 2002 Codes Chassis Code: NS (North America), RS (Europe) Introduction Market Position Positioning: The Chrysler Grand Voyager (and its Dodge Caravan/Plymouth Voyager siblings) were segment leaders in the North American minivan market, known for their practicality, spaciousness, and comfort. This 2002 model represents a refinement of a highly successful platform. Competitive Analysis Competitors: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, Buick Terraza. Key Features Features: Spacious interior, flexible seating configurations, Stow 'n Go seating (introduced later, but the platform supported innovative cargo solutions), comfortable ride, V6 engine power. Manual Details Coverage Areas Coverage: Complete service, repair, troubleshooting, and maintenance for the 2002 Chrysler Grand Voyager. Page Count Page Count: Extensive (typically 1000+ pages for comprehensive manuals of this era) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: 3.3L V6 (EGA), 3.8L V6 (L32) Transmission: 4-speed automatic (41TE/42LE) Brakes: Front disc, rear drum/disc (ABS, traction control) Suspension: Front independent, rear torsion beam/solid axle (depending on configuration) Steering: Power assisted rack and pinion Electrical: Wiring diagrams, component location, diagnostics, charging system, starting system, lighting, accessories HVAC: Air conditioning, heating, ventilation, climate control systems Body: Exterior body panels, interior trim, doors, windows, glass, power sliding doors, liftgate Safety Systems: Airbags, seat belts, ABS, traction control, immobilizer Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), component testing Repair: Engine overhaul, transmission rebuild, brake service, suspension replacement, electrical component repair Installation: Component removal and installation procedures Specifications: Torque specifications, clearances, fluid capacities, electrical specifications Technical Depth Depth: Comprehensive; covers basic maintenance to advanced engine and transmission overhaul, including detailed electrical diagnostics and bodywork repairs. Manual Specifications File Format Format: PDF Searchable Text: Yes (typical for well-digitized PDFs) Printable: Yes Print Quality Quality: High-resolution scans of original factory manuals, ensuring clarity of text and diagrams. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) Engine Specifications Primary Engine Engine 1: 3.3L OHV V6 (EGA) Engine 1 Horsepower: ~170-180 hp @ 5000 rpm (estimate) Engine 1 Torque: ~200-220 lb-ft @ 3200 rpm (estimate) Optional Engine Engine 2: 3.8L OHV V6 (L32) Engine 2 Horsepower: ~180-200 hp @ 5000 rpm (estimate) Engine 2 Torque: ~230-250 lb-ft @ 3600 rpm (estimate) Performance Fuel Type: Unleaded Gasoline Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Engine Management ECU: Chrysler's NGC (Next Generation Controller) or equivalent for the era. Transmission Standard Type 1: 4-speed Automatic (41TE / 42LE) Optional Type 2: N/A (This generation typically had the 4-speed automatic as standard across engine options). Features Overdrive: Yes (4th gear) Transmission Fluid: ATF+4 (MS-9602) recommended for optimal performance and longevity. Fluid Capacity Capacity: ~9.0 - 10.0 quarts (drain and refill, estimate) Dimensions Exterior Length: ~193-201 inches (depending on configuration) Width: ~76 inches Height: ~68 inches Interior Passenger Volume: Very spacious, typically offering 7-8 passenger capacity with multiple seating configurations. Cargo Cargo Volume Behind 1St Row: Substantial, often exceeding 100 cubic feet with rear seats removed or folded. Weights Curb Weight: ~4000-4500 lbs (estimate) Gross Vehicle Weight Rating Gvwr: ~5700-6000 lbs (estimate) Safety Features Ratings NHTSA Frontal Impact: Likely 4-star or 5-star for driver and front passenger (specific ratings vary by exact test conditions and year). The 2002 model generally performed well. IIHS Side Impact: Good or Acceptable (specific ratings vary by exact test conditions and year). Active Features ABS: Standard Anti-lock Braking System Traction Control: Optional or standard on higher trims. Passive Features Airbags: Driver and front passenger airbags. Side airbags were optional on some trims. Seat Belts: 3-point seat belts for all occupants, with pretensioners for front occupants. Technology Features Infotainment Audio System: Available AM/FM stereo with CD player, cassette player, and optional Infinity audio systems. Rear entertainment systems (DVD player) were also available on higher trims. Driver Assistance Cruise Control: Standard or available. Parking Sensors: Optional rear parking assist. Connectivity Power Outlets: Multiple 12V power outlets throughout the cabin. Maintenance Service Intervals Oil Change: Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (consult manual for specific intervals and oil type). Transmission Fluid Change: Every 30,000-60,000 miles (refer to manual for specific recommendation and interval). Spark Plugs: Typically at 60,000-100,000 miles, depending on type (e.g., platinum or iridium). Fluid Specifications Engine Oil: SAE 5W-30 is commonly recommended for both V6 engines, conforming to Chrysler MS-6395 specification. Verify in manual. Coolant: Chrysler's HOAT (Hybrid Organic Additive Technology) coolant, typically orange or red, conforming to MS-9769. Brake Fluid: DOT 3 (verify in manual) Known Issues Common Problems 1: Transmission solenoid issues (especially in earlier transmissions of this platform), power window/door lock failures, HVAC blower motor resistor failure, headliner sagging, oil cooler line leaks (on some models), rust on rocker panels and rear wheel...