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Chrysler Voyager 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Codes Chassis Code: GS (North America) 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals requiring versatile passenger and cargo space. Competitive Analysis Key Competitors: Dodge Grand Caravan, Honda Odyssey, Toyota Sienna, Ford Windstar. Key Features Versatility: Known for its spacious interior, flexible seating arrangements, and practical utility. Value Proposition: Often positioned as a more budget-friendly option within its segment. 📋 Manual Details Coverage Areas Manual Type: Full Service & Repair Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul and repair procedures for all gasoline engines, including cylinder head, block, pistons, crankshaft, timing system, lubrication, and cooling. Engine Performance: Diagnosis and repair of engine performance issues, including fuel delivery, ignition system, emissions control, and engine management systems. Transmission Automatic: Complete repair and overhaul instructions for the automatic transmission (e.g., 41TE/AE), including valve body, torque converter, planetary gears, and hydraulic systems. Transmission Manual: Repair and maintenance for manual transmission variants if applicable for the 2002 model year. Drivetrain: Front-wheel drive system, including CV joints, driveshafts, differential, and transaxle. Suspension: Front and rear suspension components, including struts, shock absorbers, control arms, ball joints, sway bars, and wheel bearings. Alignment specifications included. Steering: Power steering system diagnosis and repair, including pump, steering gear, tie rods, and power steering fluid specifications. Brakes: Front and rear disc brake systems, including calipers, rotors, pads, hydraulic lines, master cylinder, and ABS (Anti-lock Braking System) diagnosis and repair. Electrical System: Comprehensive coverage of the vehicle's electrical system, including battery, charging system (alternator), starter, ignition system, lighting, and power distribution. Body Electrical: Diagnosis and repair of body control modules (BCM), power windows, door locks, mirrors, interior and exterior lighting, and accessory circuits. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, including refrigerant handling, compressor, condenser, evaporator, and blower motor. Interior Components: Removal and installation procedures for interior trim, seats, dashboard, and console components. Exterior Body: Body panel removal and installation, including doors, hood, tailgate, fenders, bumpers, and associated hardware. Rust repair and corrosion prevention advice. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, and belt inspections. Troubleshooting: Systematic diagnostic procedures for common and complex problems, including symptom-based troubleshooting guides and diagnostic trouble codes (DTCs). Engine Rebuild: Step-by-step instructions for complete engine disassembly, inspection, machining, and reassembly. Transmission Rebuild: Detailed procedures for the overhaul of the automatic transmission, including torque specifications and assembly sequences. Brake Repair: Replacement of brake pads, rotors, calipers, and bleeding of the brake system. Electrical Diagnosis: Wiring diagrams, component testing, and troubleshooting of electrical faults. HVAC Service: Recharging the A/C system, leak detection, and component replacement. Suspension And Steering Repair: Replacement of ball joints, tie rod ends, struts, and shocks. Body And Interior Repair: Procedures for removing and installing body panels, interior trim, and seating. Technical Depth Depth Level: Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, with detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes, the PDF is likely optimized for keyword searching, allowing quick access to specific topics. Print Quality: Typically high-resolution, suitable for printing individual pages or sections. Binding Type Binding: Not Applicable (PDF Download) Paper Type Paper: Not Applicable (PDF Download) Completeness Completeness: Full Service and Repair Manual, intended to cover all aspects of vehicle maintenance and repair. ⚙️ Engine Specifications Primary Engine Engine Code Variant 1: 3.3L V6 (EGA) Displacement Variant 1: 3301 cc (201.5 cubic inches) Configuration Variant 1: Overhead Valve (OHV), 2 valves per cylinder Horsepower Variant 1: Approx. 180 hp @ 5000 rpm Torque Variant 1: Approx. 205 lb-ft @ 3200 rpm Optional Engine Engine Code Variant 2: 3.8L V6 (L32) Displacement Variant 2: 3778 cc (230.5 cubic inches) Configuration Variant 2: Overhead Valve (OHV), 2 valves per cylinder Horsepower Variant 2: Approx. 200 hp @ 4400 rpm Torque Variant 2: Approx. 240 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SEFI) Fuel Type: Unleaded gasoline, 87 octane recommended Emission Control Emission System: On-Board Diagnostics (OBD-II), catalytic converter, EGR (Exhaust Gas Recirculation). 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle (e.g., 41TE/AE) Optional Optional Transmission: Not typically offered for this model year, predominantly automatic. Features Transmission Fluid: ATF+4 (Chrysler Material Standard MS-9602) is a common specification, consult manual for exact type and capacity. Gear Ratios: Specific gear ratios for each gear and final drive would be detailed in the manual. 📐 Dimensions Exterior Length: Approx. 193.7 inches Width: Approx. 76.7 inches Height: Approx. 67.7 inches Wheelbase: Approx. 112.1 inches Interior Passenger Volume: Refer to specific trim level specifications, typically spacious for its class. Cargo Cargo Volume: Significant cargo capacity, especially with rear seats removed/folded. Exact figures vary by configuration. Weights Curb Weight: Approx....
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Sku: 67080
Collecties: ALL Chrysler Marine

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Chrysler Voyager 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
2002
Codes
Chassis Code:
GS (North America)
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, individuals requiring versatile passenger and cargo space.
Competitive Analysis
Key Competitors:
Dodge Grand Caravan, Honda Odyssey, Toyota Sienna, Ford Windstar.
Key Features
Versatility:
Known for its spacious interior, flexible seating arrangements, and practical utility.
Value Proposition:
Often positioned as a more budget-friendly option within its segment.
📋 Manual Details
Coverage Areas
Manual Type:
Full Service & Repair Manual
Language:
English
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul and repair procedures for all gasoline engines, including cylinder head, block, pistons, crankshaft, timing system, lubrication, and cooling.
Engine Performance:
Diagnosis and repair of engine performance issues, including fuel delivery, ignition system, emissions control, and engine management systems.
Transmission Automatic:
Complete repair and overhaul instructions for the automatic transmission (e.g., 41TE/AE), including valve body, torque converter, planetary gears, and hydraulic systems.
Transmission Manual:
Repair and maintenance for manual transmission variants if applicable for the 2002 model year.
Drivetrain:
Front-wheel drive system, including CV joints, driveshafts, differential, and transaxle.
Suspension:
Front and rear suspension components, including struts, shock absorbers, control arms, ball joints, sway bars, and wheel bearings. Alignment specifications included.
Steering:
Power steering system diagnosis and repair, including pump, steering gear, tie rods, and power steering fluid specifications.
Brakes:
Front and rear disc brake systems, including calipers, rotors, pads, hydraulic lines, master cylinder, and ABS (Anti-lock Braking System) diagnosis and repair.
Electrical System:
Comprehensive coverage of the vehicle's electrical system, including battery, charging system (alternator), starter, ignition system, lighting, and power distribution.
Body Electrical:
Diagnosis and repair of body control modules (BCM), power windows, door locks, mirrors, interior and exterior lighting, and accessory circuits.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, including refrigerant handling, compressor, condenser, evaporator, and blower motor.
Interior Components:
Removal and installation procedures for interior trim, seats, dashboard, and console components.
Exterior Body:
Body panel removal and installation, including doors, hood, tailgate, fenders, bumpers, and associated hardware. Rust repair and corrosion prevention advice.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, and belt inspections.
Troubleshooting:
Systematic diagnostic procedures for common and complex problems, including symptom-based troubleshooting guides and diagnostic trouble codes (DTCs).
Engine Rebuild:
Step-by-step instructions for complete engine disassembly, inspection, machining, and reassembly.
Transmission Rebuild:
Detailed procedures for the overhaul of the automatic transmission, including torque specifications and assembly sequences.
Brake Repair:
Replacement of brake pads, rotors, calipers, and bleeding of the brake system.
Electrical Diagnosis:
Wiring diagrams, component testing, and troubleshooting of electrical faults.
HVAC Service:
Recharging the A/C system, leak detection, and component replacement.
Suspension And Steering Repair:
Replacement of ball joints, tie rod ends, struts, and shocks.
Body And Interior Repair:
Procedures for removing and installing body panels, interior trim, and seating.
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, with detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes, the PDF is likely optimized for keyword searching, allowing quick access to specific topics.
Print Quality:
Typically high-resolution, suitable for printing individual pages or sections.
Binding Type
Binding:
Not Applicable (PDF Download)
Paper Type
Paper:
Not Applicable (PDF Download)
Completeness
Completeness:
Full Service and Repair Manual, intended to cover all aspects of vehicle maintenance and repair.
⚙️ Engine Specifications
Primary Engine
Engine Code Variant 1:
3.3L V6 (EGA)
Displacement Variant 1:
3301 cc (201.5 cubic inches)
Configuration Variant 1:
Overhead Valve (OHV), 2 valves per cylinder
Horsepower Variant 1:
Approx. 180 hp @ 5000 rpm
Torque Variant 1:
Approx. 205 lb-ft @ 3200 rpm
Optional Engine
Engine Code Variant 2:
3.8L V6 (L32)
Displacement Variant 2:
3778 cc (230.5 cubic inches)
Configuration Variant 2:
Overhead Valve (OHV), 2 valves per cylinder
Horsepower Variant 2:
Approx. 200 hp @ 4400 rpm
Torque Variant 2:
Approx. 240 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SEFI)
Fuel Type:
Unleaded gasoline, 87 octane recommended
Emission Control
Emission System:
On-Board Diagnostics (OBD-II), catalytic converter, EGR (Exhaust Gas Recirculation).
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle (e.g., 41TE/AE)
Optional
Optional Transmission:
Not typically offered for this model year, predominantly automatic.
Features
Transmission Fluid:
ATF+4 (Chrysler Material Standard MS-9602) is a common specification, consult manual for exact type and capacity.
Gear Ratios:
Specific gear ratios for each gear and final drive would be detailed in the manual.
📐 Dimensions
Exterior
Length:
Approx. 193.7 inches
Width:
Approx. 76.7 inches
Height:
Approx. 67.7 inches
Wheelbase:
Approx. 112.1 inches
Interior
Passenger Volume:
Refer to specific trim level specifications, typically spacious for its class.
Cargo
Cargo Volume:
Significant cargo capacity, especially with rear seats removed/folded. Exact figures vary by configuration.
Weights
Curb Weight:
Approx. 3800 - 4200 lbs depending on engine and trim.
Gross Vehicle Weight Rating:
Refer to vehicle's VIN plate for exact GVWR.
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Varies by specific test year and configuration, but generally aimed to meet or exceed contemporary safety standards. Detailed ratings would require specific testing documentation.
IIHS Crash Test:
Similarly, specific IIHS ratings would need to be sourced from their archives.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most or all trims.
Traction Control:
Optional traction control system available on some models.
Passive Features
Airbags:
Driver and front passenger airbags. Side airbags may have been optional depending on trim.
Seatbelts:
Three-point seatbelts for all outboard seating positions. Child seat anchors (LATCH) system.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player or cassette tape. Premium audio options may exist depending on trim.
Navigation System:
Factory navigation systems were not common or widely available for this model year. Aftermarket options were more prevalent.
Driver Assistance
Cruise Control:
Standard cruise control functionality.
Rear Parking Sensors:
Optional rear parking assist system may have been available on higher trims.
Connectivity
Auxiliary Input:
Factory auxiliary inputs for external audio devices were not standard. Aftermarket solutions would be required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions. Consult manual for specific recommendation.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles or as per manual, especially for heavy-duty use.
Coolant Flush:
Typically every 30,000-100,000 miles or 2-5 years, depending on coolant type.
Spark Plug Replacement:
For the V6 engines, often at 100,000 miles with platinum or iridium tipped plugs.
Fluid Specifications
Engine Oil:
SAE 5W-30 is a common recommendation for the V6 engines, consult manual for exact viscosity and API service classification (e.g., API SN or newer).
Coolant:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), typically a 50/50 mix with distilled water. Check manual for specific Mopar part number or equivalent.
Brake Fluid:
DOT 3 brake fluid.
Power Steering Fluid:
Chrysler Power Steering Fluid or a specified ATF type. Refer to manual for exact specification.
Known Issues
Transmission Hard Shifts:
Some models may experience hard shifting or transmission slippage, often related to valve body issues or low fluid levels/condition. The manual will guide diagnosis.
Idler Pulley Noise:
The serpentine belt idler pulley can sometimes become noisy and require replacement.
Headlight Switch Failure:
Intermittent headlight operation or failure of the headlight switch is a known issue on some models.
Power Sliding Door Actuator:
For models equipped with power sliding doors, the actuator mechanism can wear out and require service.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler is widely credited with pioneering the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in the mid-1980s. The Voyager nameplate has a long-standing association with family utility vehicles.
Model Evolution
Generation:
This 2002 model year falls within the second generation of the Chrysler minivan platform (GS body style), which saw significant updates and refinements over its predecessors.
Production
Manufacturing Location:
Primarily manufactured in North America, with significant production at the Windsor Assembly Plant in Windsor, Ontario, Canada.
Production Years For Gs:
1996-2000 (initial phase), with updates and facelifts continuing through to the 2007 model year for certain markets/variations, though the core GS platform was updated and eventually replaced.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
While Chrysler minivans have historically been well-regarded, specific awards for the 2002 Voyager would need to be verified through automotive publication archives.
Ratings
Consumer Reports Reliability:
Reliability ratings can vary by model year and specific components. The manual will help in identifying potential issues and their solutions.
Certifications
Epa Fuel Economy:
EPA estimates for the 2002 Voyager typically ranged from 17 MPG city / 23 MPG highway for the 3.3L V6, but exact figures depend on specific configurations and driving conditions. The manual might provide relevant specifications.
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