Chrysler Town Country 2002 Factory Service Repair Manual

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Basic Information Identification Make: Chrysler Model: Town & Country Year: 2002 Codes Chassis Code: NS Platform: Chrysler NS Platform Introduction Market Position Segment: Full-size minivan Target Audience: Families, fleet operators, DIY mechanics, professional repair shops. Competitive Analysis Key Competitors 2002: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Mercury Monterey. Key Features Vehicle Type: Minivan Seating Capacity: Typically 7-8 passengers depending on configuration. Storage Innovation: Features like Stow 'n Go seating (introduced later, but concept of versatile interior was key). Manual Purpose Purpose: To provide complete diagnostic, repair, maintenance, and specification data for the 2002 Chrysler Town & Country. Manual Details Coverage Areas Diagnostic Procedures: Comprehensive diagnostic procedures for all major systems. Repair Procedures: Detailed step-by-step repair procedures for mechanical and electrical components. Maintenance Schedules: Factory-recommended maintenance schedules for various mileage and time intervals. Wiring Diagrams: Complete electrical system wiring diagrams. Component Locations: Detailed diagrams showing the location of all major components. Troubleshooting Guides: Extensive troubleshooting charts and symptom-based diagnostic trees. Page Count Estimated Pages: Hundreds of pages (exact count not specified, but implies comprehensive coverage). Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, block assembly, crankshaft, pistons, connecting rods, timing system. Engine Performance: Fuel system, ignition system, emissions control system, cooling system, lubrication system. Transmission Automatic: 41TE Transmission: Overhaul, diagnostics, fluid specifications, torque converter, valve body. Brakes: Front disc brakes, rear drum brakes, Anti-lock Braking System (ABS), brake fluid specifications. Steering: Power steering system, steering gear, steering column, alignment specifications. Suspension: Front suspension (McPherson struts), rear suspension (torsion beam axle), shock absorbers, springs, wheel bearings. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, instrument cluster, power windows/locks, mirrors. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor. Body: Body construction, exterior trim, doors, hood, liftgate, interior trim, seat mechanisms, glass. Restraint Systems: Airbag system, seat belts, SRS module. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement. Troubleshooting Diagnostics: System-specific diagnostic flowcharts and fault code interpretations. Component Repair Overhaul: Detailed procedures for repairing or overhauling major components like engines and transmissions. Electrical Component Replacement: Replacement of alternators, starters, sensors, control modules, etc. Brake System Service: Brake pad/shoe replacement, caliper/wheel cylinder service, brake bleeding. Suspension Component Replacement: Strut replacement, ball joint service, tie rod end replacement. HVAC System Service: Recharge procedures, component replacement, leak detection. Body Panel Repair Replacement: Procedures for removing and installing body panels, doors, and liftgate. Safety System Diagnostics: Airbag system diagnostics and component replacement. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including diagnostics and troubleshooting. Manual Specifications File Format File Type: PDF Searchable Text: Likely searchable due to PDF format, facilitating quick access to information. Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) Engine Specifications Primary Engine Engine Name: 3.3L V6 OHV Engine Code: EGA Displacement: 3.3 Liters (203 cubic inches) Configuration: V-shaped, 6 cylinders Valvetrain: Overhead Valve (OHV), 2 valves per cylinder Bore X Stroke: 3.92 in x 3.58 in (99.5 mm x 90.9 mm) Compression Ratio: 8.9:1 Horsepower: 180 hp @ 5000 rpm (approx.) Torque: 205 lb-ft @ 4000 rpm (approx.) Fuel System Induction: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Cooling System Coolant Capacity: Approx. 11.5 quarts (10.9 Liters) with 50/50 antifreeze/water mix. Lubrication System Oil Capacity: Approx. 4.5 quarts (4.3 Liters) with filter change. Recommended Oil: SAE 5W-30 API certified engine oil. Ignition System Spark Plugs: Champion REC10ZPYPB4 (or equivalent). Engine Management PCM Type: Specific PCM part number detailed in manual. Transmission Standard Transmission Type: 4-speed Automatic Transaxle Model Code: 41TE Features Torque Converter: Lock-up torque converter. Fluid Capacity Fluid Capacity: Approx. 10.3 quarts (9.7 Liters) for total capacity, 7.0 quarts (6.6 Liters) for refill after pan drop. Fluid Specification Fluid Type: ATF+4 (Automatic Transmission Fluid type 4). Gear Ratios Final Drive Ratio: 3.58:1 Dimensions Exterior Length: Approx. 197.5 inches (5017 mm) Width: Approx. 77.1 inches (1958 mm) Height: Approx. 68.7 inches (1745 mm) Wheelbase: Approx. 119.8 inches (3043 mm) Interior Passenger Volume: Approx. 140.7 cu ft (3984 L) Cargo Cargo Volume Behind 3Rd Row: Approx. 39.0 cu ft (1104 L) Cargo Volume Behind 2Nd Row: Approx. 83.0 cu ft (2350 L) Cargo Volume Behind 1St Row: Approx. 126.0 cu ft (3568 L) Weights Curb Weight: Approx. 4,100 - 4,300 lbs (1860 - 1950 kg), varies by trim and options. Gross Vehicle Weight Rating: Approx. 5,700 - 5,900 lbs (2585 - 2676 kg). Safety Features Ratings NHTSA Front Driver: 4/5 stars (for 2002 model year, specific tests may vary). NHTSA Front Passenger: 4/5 stars (for 2002 model...

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Description

Basic Information
Identification
Make:	Chrysler
Model:	Town & Country
Year:	2002
Codes
Chassis Code:	NS
Platform:	Chrysler NS Platform

Introduction
Market Position
Segment:	Full-size minivan
Target Audience:	Families, fleet operators, DIY mechanics, professional repair shops.
Competitive Analysis
Key Competitors 2002:	Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Mercury Monterey.
Key Features
Vehicle Type:	Minivan
Seating Capacity:	Typically 7-8 passengers depending on configuration.
Storage Innovation:	Features like Stow 'n Go seating (introduced later, but concept of versatile interior was key).
Manual Purpose
Purpose:	To provide complete diagnostic, repair, maintenance, and specification data for the 2002 Chrysler Town & Country.

Manual Details
Coverage Areas
Diagnostic Procedures:	Comprehensive diagnostic procedures for all major systems.
Repair Procedures:	Detailed step-by-step repair procedures for mechanical and electrical components.
Maintenance Schedules:	Factory-recommended maintenance schedules for various mileage and time intervals.
Wiring Diagrams:	Complete electrical system wiring diagrams.
Component Locations:	Detailed diagrams showing the location of all major components.
Troubleshooting Guides:	Extensive troubleshooting charts and symptom-based diagnostic trees.
Page Count
Estimated Pages:	Hundreds of pages (exact count not specified, but implies comprehensive coverage).
Manual Type
Type:	Factory Service Manual / Repair Manual
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanical:	Engine removal/installation, cylinder head, block assembly, crankshaft, pistons, connecting rods, timing system.
Engine Performance:	Fuel system, ignition system, emissions control system, cooling system, lubrication system.
Transmission Automatic:	41TE Transmission: Overhaul, diagnostics, fluid specifications, torque converter, valve body.
Brakes:	Front disc brakes, rear drum brakes, Anti-lock Braking System (ABS), brake fluid specifications.
Steering:	Power steering system, steering gear, steering column, alignment specifications.
Suspension:	Front suspension (McPherson struts), rear suspension (torsion beam axle), shock absorbers, springs, wheel bearings.
Electrical System:	Battery, charging system (alternator), starting system (starter motor), lighting system, instrument cluster, power windows/locks, mirrors.
HVAC:	Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor.
Body:	Body construction, exterior trim, doors, hood, liftgate, interior trim, seat mechanisms, glass.
Restraint Systems:	Airbag system, seat belts, SRS module.
Procedures Included
Routine Maintenance:	Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement.
Troubleshooting Diagnostics:	System-specific diagnostic flowcharts and fault code interpretations.
Component Repair Overhaul:	Detailed procedures for repairing or overhauling major components like engines and transmissions.
Electrical Component Replacement:	Replacement of alternators, starters, sensors, control modules, etc.
Brake System Service:	Brake pad/shoe replacement, caliper/wheel cylinder service, brake bleeding.
Suspension Component Replacement:	Strut replacement, ball joint service, tie rod end replacement.
HVAC System Service:	Recharge procedures, component replacement, leak detection.
Body Panel Repair Replacement:	Procedures for removing and installing body panels, doors, and liftgate.
Safety System Diagnostics:	Airbag system diagnostics and component replacement.
Technical Depth
Depth:	Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including diagnostics and troubleshooting.

Manual Specifications
File Format
File Type:	PDF
Searchable Text:	Likely searchable due to PDF format, facilitating quick access to information.
Print Quality
Quality:	High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:	N/A (Digital PDF Download)
Paper Type
Paper:	N/A (Digital PDF Download)

Engine Specifications
Primary Engine
Engine Name:	3.3L V6 OHV
Engine Code:	EGA
Displacement:	3.3 Liters (203 cubic inches)
Configuration:	V-shaped, 6 cylinders
Valvetrain:	Overhead Valve (OHV), 2 valves per cylinder
Bore X Stroke:	3.92 in x 3.58 in (99.5 mm x 90.9 mm)
Compression Ratio:	8.9:1
Horsepower:	180 hp @ 5000 rpm (approx.)
Torque:	205 lb-ft @ 4000 rpm (approx.)
Fuel System
Induction:	Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:	Unleaded Gasoline (87 octane recommended)
Cooling System
Coolant Capacity:	Approx. 11.5 quarts (10.9 Liters) with 50/50 antifreeze/water mix.
Lubrication System
Oil Capacity:	Approx. 4.5 quarts (4.3 Liters) with filter change.
Recommended Oil:	SAE 5W-30 API certified engine oil.
Ignition System
Spark Plugs:	Champion REC10ZPYPB4 (or equivalent).
Engine Management
PCM Type:	Specific PCM part number detailed in manual.

Transmission
Standard
Transmission Type:	4-speed Automatic Transaxle
Model Code:	41TE
Features
Torque Converter:	Lock-up torque converter.
Fluid Capacity
Fluid Capacity:	Approx. 10.3 quarts (9.7 Liters) for total capacity, 7.0 quarts (6.6 Liters) for refill after pan drop.
Fluid Specification
Fluid Type:	ATF+4 (Automatic Transmission Fluid type 4).
Gear Ratios
Final Drive Ratio:	3.58:1

Dimensions
Exterior
Length:	Approx. 197.5 inches (5017 mm)
Width:	Approx. 77.1 inches (1958 mm)
Height:	Approx. 68.7 inches (1745 mm)
Wheelbase:	Approx. 119.8 inches (3043 mm)
Interior
Passenger Volume:	Approx. 140.7 cu ft (3984 L)
Cargo
Cargo Volume Behind 3Rd Row:	Approx. 39.0 cu ft (1104 L)
Cargo Volume Behind 2Nd Row:	Approx. 83.0 cu ft (2350 L)
Cargo Volume Behind 1St Row:	Approx. 126.0 cu ft (3568 L)
Weights
Curb Weight:	Approx. 4,100 - 4,300 lbs (1860 - 1950 kg), varies by trim and options.
Gross Vehicle Weight Rating:	Approx. 5,700 - 5,900 lbs (2585 - 2676 kg).

Safety Features
Ratings
NHTSA Front Driver:	4/5 stars (for 2002 model year, specific tests may vary).
NHTSA Front Passenger:	4/5 stars (for 2002 model year, specific tests may vary).
IIHS Front Impact:	Good (for vehicles of this type/era).
Active Features
ABS:	Standard Anti-lock Braking System (ABS).
Traction Control:	Optional (often part of ESC on higher trims or later models, but less common on base 2002).
Passive Features
Airbags Front:	Standard multi-stage front airbags.
Airbags Side:	Optional front-seat side airbags.
Seat Belts:	Three-point seat belts for all seating positions.
Child Seat Anchors:	LATCH (Lower Anchors and Tethers for CHildren) system.

Technology Features
Infotainment
Audio System:	AM/FM stereo with CD player, optional cassette player, optional rear-seat entertainment system.
Navigation:	Optional factory-installed navigation system.
Driver Assistance
Parking Sensors:	Optional rear parking assist system.
Connectivity
Remote Keyless Entry:	Standard or optional depending on trim level.
Power Sliding Doors:	Optional power sliding doors for passenger convenience.

Maintenance
Service Intervals
Oil And Filter Change:	Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).
Engine Air Filter:	Inspect every 15,000 miles (24,000 km), replace as needed. Usually recommended at 30,000 miles (48,000 km).
Cabin Air Filter:	Inspect/replace annually or every 15,000 miles (24,000 km).
Transmission Fluid:	Check at every oil change. Replace every 60,000 miles (96,000 km) or 48 months.
Coolant:	Inspect level and condition regularly. Flush and replace every 5 years or 100,000 miles (160,000 km).
Spark Plugs:	Recommended replacement at 100,000 miles (160,000 km) if using original type (long-life).
Fluid Specifications
Brake Fluid:	DOT 3.
Power Steering Fluid:	Mopar Power Steering Fluid or equivalent.
Windshield Washer Fluid:	Commercial washer fluid or water/antifreeze mix.
Known Issues
Common Problem 1:	Transmission solenoid issues leading to shifting problems.
Common Problem 2:	Coolant leaks, particularly from the water pump or heater core.
Common Problem 3:	Front suspension component wear (ball joints, struts).
Common Problem 4:	Power window regulator failures.
Common Problem 5:	HVAC blower motor failures.

Vehicle History
Brand Heritage
Brand Origin:	Chrysler Corporation, founded in 1925 by Walter Chrysler.
Model Evolution
Original Town Country Introduction:	First introduced in 1941 as a 'woodie' wagon; revived as a minivan in 1984.
Generation 2001-2007:	The 2002 model belongs to the fourth generation of the Chrysler minivan, marking a significant redesign from the previous generation.
Production
Manufacturing Plant:	Windsor Assembly Plant, Windsor, Ontario, Canada.
Production Years
Model Year Range:	2001-2007 (This generation)

Awards & Recognition
Recognitions
Critical Acclaim:	Chrysler minivans have historically been well-regarded for their practicality and family-friendly features, though specific awards for the 2002 model year would need to be researched from automotive publications of that era.