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Chrysler Voyager 2002 Factory Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Codes Platform: NS/RS 👋 Introduction Market Position Vehicle Segment: Full-size Minivan Target Audience: Families, commercial use, fleet operators Competitive Analysis Key Competitors: Dodge Grand Caravan, Ford Windstar, Honda Odyssey, Toyota Sienna Key Features Interior Versatility: Flexible seating arrangements, ample cargo space, Stow 'n Go (later models, but design philosophy present) Powertrain Options: Reliable V6 engines known for torque and towing capacity Ride Comfort: Tuned for comfortable long-distance cruising 📋 Manual Details Coverage Areas Manual Type: Factory Repair Manual Language: English Format: Digital (likely PDF, verifiable upon acquisition) Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for a comprehensive factory manual of this era) 📖 Manual Coverage Systems Covered Engine Service: Complete diagnostic, repair, and overhaul procedures for all engine variants Transmission Service: Detailed procedures for automatic transmission diagnosis, repair, and maintenance Brake System: Diagnosis and repair of ABS, hydraulic components, parking brake, and rotor/pad replacement Suspension Steering: Front and rear suspension components, steering gear, power steering system, alignment specifications Electrical System: Wiring diagrams, component testing, starter, alternator, battery, lighting, power windows, locks, and accessories HVAC: Air conditioning system diagnosis, refrigerant handling, heater core, blower motor, climate control Body And Trim: Exterior panel repair, interior trim removal and installation, glass replacement Diagnostic Troubleshooting: Systematic fault finding and diagnostic procedures for all major vehicle systems Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, evaporative emissions system Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors Cooling System: Radiator, fan, thermostat, water pump, coolant hoses, heater core Procedures Included Routine Maintenance: Oil change, filter replacement, fluid checks, tire rotation, tune-up procedures Component Replacement: Step-by-step instructions for replacing major components (e.g., water pump, alternator, starter, fuel pump) Engine Rebuild: Detailed specifications and procedures for engine disassembly, inspection, and reassembly Transmission Overhaul: Complete overhaul procedures for the automatic transmission, including clutch pack replacement and valve body service Brake System Repair: Front and rear brake pad and rotor replacement, caliper service, brake line bleeding Electrical Component Testing: Testing procedures for sensors, actuators, ignition system components, and body control modules Diagnostics Trouble Codes: Interpretation and troubleshooting of all diagnostic trouble codes (DTCs) relevant to the 2002 model year Wheel Bearing Replacement: Procedures for front and rear wheel bearing replacement Technical Depth Diagnostic Capabilities: Comprehensive diagnostic flowcharts, trouble codes (DTCs), and symptom-based troubleshooting Repair Complexity: Covers basic DIY maintenance to complex mechanical and electrical repairs requiring specialized tools Specification Accuracy: Includes precise torque specifications, clearances, fluid capacities, and electrical resistance values Wiring Diagrams: Includes detailed, system-specific wiring diagrams for accurate electrical troubleshooting 📊 Manual Specifications File Format Digital Format: PDF (typically, high-resolution scans of original factory documentation) Print Quality Scan Quality: High-resolution scans ensuring readability of text, diagrams, and illustrations Binding Type Digital Format Advantage: Searchable text and easy navigation via bookmarks, no physical binding concerns Paper Type Original Document Type: Factory-produced technical documentation on durable paper stock ⚙️ Engine Specifications Primary Engine Engine Code: EGA (3.3L V6) Displacement: 3.3 Liters (204 cubic inches) Configuration: SOHC V6 Horsepower: 180 hp @ 5000 rpm (approx.) Torque: 200 lb-ft @ 3200 rpm (approx.) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Performance Engine Variant 2: Optional: 3.8L V6 (EPH code), 190-200 hp, 230-235 lb-ft torque (check specific vehicle VIN) Maintenance Items Spark Plugs: Champion RC12LYC or equivalent (gap 0.045") Engine Oil Type: SAE 5W-30 API Certified Engine Oil Capacity: 4.5 US quarts (4.3 Liters) with filter 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transmission Model: Chrysler 41TE / 42LE Features Overdrive: Yes (4th gear) Transmission Fluid Type: ATF+4 (Mopar) Maintenance Items Transmission Fluid Capacity: Approximately 4.0 US quarts (3.8 Liters) for fluid change with filter replacement 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 195.8 inches (4973 mm) Width: 76.7 inches (1948 mm) Height: 68.4 inches (1737 mm) Weights Curb Weight: Approx. 4100-4300 lbs (depending on configuration) Gross Vehicle Weight Rating Gvwr: Approx. 5700-5900 lbs Cargo Cargo Volume Behind 3Rd Row: Approx. 15 cubic feet Cargo Volume Behind 2Nd Row: Approx. 57 cubic feet Cargo Volume Max: Approx. 145 cubic feet Towing Towing Capacity: Up to 3800 lbs (with optional towing package and proper trailer weight distribution) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: ★★★★ (4 Stars) NHTSA Frontal Impact Passenger: ★★★★ (4 Stars) IIHS Frontal Offset: Good Active Features ABS: Standard Anti-lock Braking System Traction Control: Optional Traction Control System (TCS) Passive Features Airbags: Front driver and passenger airbags; Optional front-side airbags Seat Belts: 3-point seat belts for all occupants, driver's seatbelt reminder 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD or Cassette/CD player options; premium Infinity sound system available Rear Entertainment: Optional rear-seat entertainment system with video screen and headphone jacks Driver Assistance Cruise Control: Standard cruise control Connectivity Power Accessories: Power windows, power door...
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Sku: 584081
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Chrysler Voyager 2002 Factory Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
2002
Codes
Platform:
NS/RS
👋 Introduction
Market Position
Vehicle Segment:
Full-size Minivan
Target Audience:
Families, commercial use, fleet operators
Competitive Analysis
Key Competitors:
Dodge Grand Caravan, Ford Windstar, Honda Odyssey, Toyota Sienna
Key Features
Interior Versatility:
Flexible seating arrangements, ample cargo space, Stow 'n Go (later models, but design philosophy present)
Powertrain Options:
Reliable V6 engines known for torque and towing capacity
Ride Comfort:
Tuned for comfortable long-distance cruising
📋 Manual Details
Coverage Areas
Manual Type:
Factory Repair Manual
Language:
English
Format:
Digital (likely PDF, verifiable upon acquisition)
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for a comprehensive factory manual of this era)
📖 Manual Coverage
Systems Covered
Engine Service:
Complete diagnostic, repair, and overhaul procedures for all engine variants
Transmission Service:
Detailed procedures for automatic transmission diagnosis, repair, and maintenance
Brake System:
Diagnosis and repair of ABS, hydraulic components, parking brake, and rotor/pad replacement
Suspension Steering:
Front and rear suspension components, steering gear, power steering system, alignment specifications
Electrical System:
Wiring diagrams, component testing, starter, alternator, battery, lighting, power windows, locks, and accessories
HVAC:
Air conditioning system diagnosis, refrigerant handling, heater core, blower motor, climate control
Body And Trim:
Exterior panel repair, interior trim removal and installation, glass replacement
Diagnostic Troubleshooting:
Systematic fault finding and diagnostic procedures for all major vehicle systems
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injectors, evaporative emissions system
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors
Cooling System:
Radiator, fan, thermostat, water pump, coolant hoses, heater core
Procedures Included
Routine Maintenance:
Oil change, filter replacement, fluid checks, tire rotation, tune-up procedures
Component Replacement:
Step-by-step instructions for replacing major components (e.g., water pump, alternator, starter, fuel pump)
Engine Rebuild:
Detailed specifications and procedures for engine disassembly, inspection, and reassembly
Transmission Overhaul:
Complete overhaul procedures for the automatic transmission, including clutch pack replacement and valve body service
Brake System Repair:
Front and rear brake pad and rotor replacement, caliper service, brake line bleeding
Electrical Component Testing:
Testing procedures for sensors, actuators, ignition system components, and body control modules
Diagnostics Trouble Codes:
Interpretation and troubleshooting of all diagnostic trouble codes (DTCs) relevant to the 2002 model year
Wheel Bearing Replacement:
Procedures for front and rear wheel bearing replacement
Technical Depth
Diagnostic Capabilities:
Comprehensive diagnostic flowcharts, trouble codes (DTCs), and symptom-based troubleshooting
Repair Complexity:
Covers basic DIY maintenance to complex mechanical and electrical repairs requiring specialized tools
Specification Accuracy:
Includes precise torque specifications, clearances, fluid capacities, and electrical resistance values
Wiring Diagrams:
Includes detailed, system-specific wiring diagrams for accurate electrical troubleshooting
📊 Manual Specifications
File Format
Digital Format:
PDF (typically, high-resolution scans of original factory documentation)
Print Quality
Scan Quality:
High-resolution scans ensuring readability of text, diagrams, and illustrations
Binding Type
Digital Format Advantage:
Searchable text and easy navigation via bookmarks, no physical binding concerns
Paper Type
Original Document Type:
Factory-produced technical documentation on durable paper stock
⚙️ Engine Specifications
Primary Engine
Engine Code:
EGA (3.3L V6)
Displacement:
3.3 Liters (204 cubic inches)
Configuration:
SOHC V6
Horsepower:
180 hp @ 5000 rpm (approx.)
Torque:
200 lb-ft @ 3200 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Performance
Engine Variant 2:
Optional: 3.8L V6 (EPH code), 190-200 hp, 230-235 lb-ft torque (check specific vehicle VIN)
Maintenance Items
Spark Plugs:
Champion RC12LYC or equivalent (gap 0.045")
Engine Oil Type:
SAE 5W-30 API Certified
Engine Oil Capacity:
4.5 US quarts (4.3 Liters) with filter
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic
Transmission Model:
Chrysler 41TE / 42LE
Features
Overdrive:
Yes (4th gear)
Transmission Fluid Type:
ATF+4 (Mopar)
Maintenance Items
Transmission Fluid Capacity:
Approximately 4.0 US quarts (3.8 Liters) for fluid change with filter replacement
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
195.8 inches (4973 mm)
Width:
76.7 inches (1948 mm)
Height:
68.4 inches (1737 mm)
Weights
Curb Weight:
Approx. 4100-4300 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Approx. 5700-5900 lbs
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 15 cubic feet
Cargo Volume Behind 2Nd Row:
Approx. 57 cubic feet
Cargo Volume Max:
Approx. 145 cubic feet
Towing
Towing Capacity:
Up to 3800 lbs (with optional towing package and proper trailer weight distribution)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
★★★★ (4 Stars)
NHTSA Frontal Impact Passenger:
★★★★ (4 Stars)
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Optional Traction Control System (TCS)
Passive Features
Airbags:
Front driver and passenger airbags; Optional front-side airbags
Seat Belts:
3-point seat belts for all occupants, driver's seatbelt reminder
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette/CD player options; premium Infinity sound system available
Rear Entertainment:
Optional rear-seat entertainment system with video screen and headphone jacks
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors were common features
Convenience
Remote Keyless Entry:
Available remote keyless entry system
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (under normal driving conditions)
Transmission Fluid Change:
Every 30,000 miles or 24 months (recommended service, especially for heavy use)
Coolant Change:
Initial change at 100,000 miles, then every 50,000 miles (or every 5 years)
Spark Plug Replacement:
Every 100,000 miles (long-life platinum or iridium plugs)
Fluid Specifications
Power Steering Fluid:
ATF+4 (Mopar)
Coolant Type:
Chrysler OAT (Organic Acid Technology) HOAT (Hybrid OAT) Pink or equivalent long-life antifreeze
Brake Fluid Type:
DOT 3
Known Issues
Transmission Solenoids:
Intermittent shifting issues or no-shift condition can be related to failing solenoids in the 41TE/42LE transmission
Water Pump Leaks:
Common for the water pump to develop leaks over time, often requiring replacement
Power Window Motors:
Failure of power window motors and regulators is a relatively common issue
Rear Wiper Motor:
The rear wiper motor assembly can corrode and fail
Cv Axle Boots:
Torn CV axle boots can lead to joint failure if not addressed promptly
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler is credited with inventing the modern minivan segment with the 1984 Dodge Caravan/Plymouth Voyager
Model Evolution
Ns Generation:
The 2002 model year falls within the second generation (NS platform, 1996-2000) and the first year of the third generation (RS platform, 2001-2007) for the Chrysler Voyager. This manual likely covers the RS generation transition or specifically the 2002 RS model.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Model Year Context:
2002 marked a significant redesign and introduction of the RS platform, featuring updated styling, chassis, and interior.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The original Chrysler minivan was a recurring recipient of Car and Driver's 10Best awards; the 2002 model continued to be a strong contender in its segment.
Ratings
Consumer Reports:
Often rated as average to above average for its class in reliability and owner satisfaction, though specific year ratings can vary.
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