Chrysler Voyager 2001 2002 Service Repair Workshop Manual
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The Chrysler Voyager, produced for the 2001-2002 model years, is a mid-size minivan recognized for its spacious interior, comfortable ride, and versatile seating configurations, making it a popular choice for families. Built on the NS platform, this vehicle offered powerful V6 engine options, including the 3.3L EGW and the 3.8L U, both featuring sequential multi-port fuel injection. Chrysler's long-standing heritage in minivan innovation is evident in the Voyager's design, which evolved from its groundbreaking predecessors. With its family-oriented features and a strong market presence against competitors like the Dodge Grand Caravan and Honda Odyssey, the Voyager solidified its position as a reliable and practical transportation solution. This comprehensive factory service manual provides in-depth guidance for the maintenance, repair, and diagnostics of the Chrysler Voyager (2001-2002), covering all trim levels. The manual details engine mechanicals, cooling, lubrication, fuel delivery, ignition, emissions, and electrical systems, as well as automatic transmission, drivetrain, suspension, steering, and brake systems. It includes essential procedures for routine maintenance, component repair, and troubleshooting, supported by detailed technical specifications, torque values, and electrical wiring diagrams. The purpose of this manual is to equip owners, technicians, and mechanics with the factory-level knowledge necessary to effectively maintain and repair the vehicle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2001-2002 Codes Platform: NS (Minivan) 👋 Introduction Market Position Vehicle Segment: Mid-size Minivan Target Audience: Families seeking versatile and comfortable transportation Competitive Analysis Key Competitors: Dodge Grand Caravan, Ford Windstar, Honda Odyssey, Toyota Sienna Key Features Vehicle Strengths: Spacious interior, comfortable ride, versatile seating configurations, powerful V6 engine options Manual Value Proposition: Empowers owners and independent technicians with factory-level repair and maintenance knowledge, reducing reliance on expensive dealership service. 📋 Manual Details Coverage Areas Region Coverage: Global (North America, Europe, Australia) Trim Level Coverage: All trim levels including base, SE, LX, EX Page Count Estimated Pages: 1500-2000 (typical for comprehensive service manuals of this era) Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, cooling, lubrication, fuel delivery, ignition, emissions control, engine electrical, starting, charging Transmission Systems: Automatic transmission (e.g., 41TE/42LE), clutch operation (if applicable to specific variants), transmission control module (TCM) Drivetrain Systems: Front-wheel drive (FWD) system, driveshafts, differentials Suspension Systems: Front suspension (struts, control arms, ball joints), rear suspension (torsion beam or independent depending on specific variant), wheel alignment specifications Steering Systems: Power steering system, steering column, steering gear/rack and pinion Brake Systems: Front and rear brake components (discs/drums), hydraulic system, anti-lock braking system (ABS) diagnostics and repair Electrical Systems: Battery, starting system, charging system, lighting system, instrument cluster, wiring diagrams, Body Control Module (BCM), Powertrain Control Module (PCM) HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, climate control operation Body And Interior: Body panels, doors, windows, seats, interior trim, sunroof (if equipped), liftgate Safety Systems: Airbag system (SRS) diagnostics and repair, seat belt mechanisms Procedures Included Maintenance Procedures: Oil change, filter replacement, fluid level checks and top-offs, spark plug replacement, air filter replacement, brake fluid flush, coolant flush Repair Procedures: Engine component repair (e.g., head gasket, timing belt/chain), transmission overhaul, brake component replacement (rotors, pads, calipers), suspension component replacement (shocks, struts, ball joints), steering system repair, electrical component troubleshooting and replacement Diagnostic Procedures: Troubleshooting guides based on symptoms, diagnostic trouble code (DTC) interpretation, testing of electrical circuits and sensors, fuel system pressure testing Technical Specifications Charts: Torque specifications for all fasteners, engine data, electrical system specifications, diagnostic parameters Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems Troubleshooting Trees: Step-by-step diagnostic flowcharts for common problems Technical Depth Depth Of Information: Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and detailed electrical system repair. 📊 Manual Specifications File Format File Format: PDF Searchability: Text-searchable PDF for quick information retrieval Print Quality Image Resolution: High-resolution images and diagrams suitable for printing Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EGW (3.3L V6 OHV) Engine Displacement 1: 3.3 Liters (3301 cc) Engine Configuration 1: V6, 60-degree bank angle Engine Horsepower 1: 158 hp @ 4500 rpm (approx.) Engine Torque 1: 205 lb-ft @ 3000 rpm (approx.) Engine Variants Engine Code 2: U (3.8L V6 OHV) Engine Displacement 2: 3.8 Liters (3778 cc) Engine Horsepower 2: 180 hp @ 4500 rpm (approx.) Engine Torque 2: 235 lb-ft @ 3000 rpm (approx.) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management Engine Control Module ECM: Powertrain Control Module (PCM) 🔧 Transmission Standard Transmission Transmission Type: 4-speed Automatic Transaxle Transmission Model 1: 41TE / 42LE Optional Transmission Optional Transmission Availability: N/A (Automatic was standard) Features Transmission Features:...
The Chrysler Voyager, produced for the 2001-2002 model years, is a mid-size minivan recognized for its spacious interior, comfortable ride, and versatile seating configurations, making it a popular choice for families. Built on the NS platform, this vehicle offered powerful V6 engine options, including the 3.3L EGW and the 3.8L U, both featuring sequential multi-port fuel injection. Chrysler's long-standing heritage in minivan innovation is evident in the Voyager's design, which evolved from its groundbreaking predecessors. With its family-oriented features and a strong market presence against competitors like the Dodge Grand Caravan and Honda Odyssey, the Voyager solidified its position as a reliable and practical transportation solution.
This comprehensive factory service manual provides in-depth guidance for the maintenance, repair, and diagnostics of the Chrysler Voyager (2001-2002), covering all trim levels. The manual details engine mechanicals, cooling, lubrication, fuel delivery, ignition, emissions, and electrical systems, as well as automatic transmission, drivetrain, suspension, steering, and brake systems. It includes essential procedures for routine maintenance, component repair, and troubleshooting, supported by detailed technical specifications, torque values, and electrical wiring diagrams. The purpose of this manual is to equip owners, technicians, and mechanics with the factory-level knowledge necessary to effectively maintain and repair the vehicle, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
2001-2002
Codes
Platform:
NS (Minivan)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Minivan
Target Audience:
Families seeking versatile and comfortable transportation
Competitive Analysis
Key Competitors:
Dodge Grand Caravan, Ford Windstar, Honda Odyssey, Toyota Sienna
Front suspension (struts, control arms, ball joints), rear suspension (torsion beam or independent depending on specific variant), wheel alignment specifications
Steering Systems:
Power steering system, steering column, steering gear/rack and pinion
Brake Systems:
Front and rear brake components (discs/drums), hydraulic system, anti-lock braking system (ABS) diagnostics and repair
Electrical Systems:
Battery, starting system, charging system, lighting system, instrument cluster, wiring diagrams, Body Control Module (BCM), Powertrain Control Module (PCM)
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, climate control operation
Troubleshooting guides based on symptoms, diagnostic trouble code (DTC) interpretation, testing of electrical circuits and sensors, fuel system pressure testing
Technical Specifications Charts:
Torque specifications for all fasteners, engine data, electrical system specifications, diagnostic parameters
Wiring Diagrams:
Detailed electrical wiring schematics for all vehicle systems
Troubleshooting Trees:
Step-by-step diagnostic flowcharts for common problems
Technical Depth
Depth Of Information:
Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and detailed electrical system repair.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Text-searchable PDF for quick information retrieval
Print Quality
Image Resolution:
High-resolution images and diagrams suitable for printing
Approx. 8.0 - 9.5 quarts (7.6 - 9.0 liters) for a dry fill
📐 Dimensions
Exterior
Wheelbase:
113.1 inches (2873 mm)
Length:
193.9 inches (4925 mm)
Width:
76.9 inches (1953 mm)
Height:
68.3 inches (1735 mm)
Weights
Curb Weight Range:
Approx. 4000-4400 lbs (1814-1996 kg) depending on configuration
Gross Vehicle Weight Rating Gvwr:
Approx. 5700-6000 lbs (2585-2722 kg)
Cargo
Cargo Volume Behind 1St Row:
Approx. 150 cu. ft. (4.25 m³)
Cargo Volume Behind 2Nd Row:
Approx. 85 cu. ft. (2.41 m³)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating 2001:
Four-star (driver and passenger front-seat side-impact occupant protection)
IIHS Small Overlap Front Rating:
Not rated (as this test was not prevalent for this era)
Active Features
ABS Availability:
Optional on most trims, standard on higher trims
Passive Features
Airbag System:
Driver and front passenger airbags (SRS)
Seatbelt Type:
Three-point seat belts for all seating positions
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system
💡 Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, cassette player, and optional premium sound systems.
Rear Entertainment:
Optional rear-seat entertainment system with video cassette player (VCP) or early DVD players on some higher trims.
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Power Accessories:
Power windows, power door locks, available power sliding doors, power liftgate.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months, or 7,500 miles (12,000 km) / 6 months with synthetic oil (refer to manual for specific recommendations).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for conventional plugs, potentially longer for platinum/iridium
Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 24 months, especially under severe operating conditions
Coolant Flush:
Every 30,000 miles (48,000 km) or 24 months
Fluid Specifications
Engine Oil Specification:
API Service SG or SH, SAE 5W-30 or 10W-30 (refer to manual for climate-specific recommendations)
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter for 3.3L V6; Approx. 5.0 quarts (4.7 liters) with filter for 3.8L V6
Coolant Type:
Chrysler/Mopar Antifreeze/Coolant (Green 50/50 mix with distilled water)
Brake Fluid Type:
DOT 3
Known Issues
Common Issues Engine:
Head gasket leaks, intake manifold gasket leaks, oil filter housing leaks, occasional spark plug blow-out on some engines.
Common Issues Transmission:
Torque converter shudder, transmission fluid leaks, issues with the transmission control solenoid.
Common Issues Suspension:
Worn front control arm bushings, worn ball joints, premature tie rod end wear.
Common Issues Electrical:
Faulty window regulators, issues with the power sliding door mechanism, intermittent HVAC blower motor operation.
📚 Vehicle History
Brand Heritage
Brand History Note:
Chrysler has a long history in automotive manufacturing, particularly known for its innovations in the minivan segment.
Model Evolution
Voyager Model Context:
The Chrysler Voyager is part of the Dodge Caravan/Plymouth Voyager family, representing Chrysler's pioneering efforts and market dominance in minivans starting in the mid-1980s.
Generation Ns:
This generation (NS) was introduced for the 1996 model year and received a facelift for the 2001 model year, encompassing the years covered by this manual.
Production
Production Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years For This Generation:
1996-2007 (with significant updates)
🏆 Awards & Recognition
Recognitions
Car And Driver Best List:
The Chrysler minivan platform (including Voyager/Grand Caravan) has been a frequent recipient of '10 Best' lists from publications like Car and Driver in earlier iterations, establishing its segment leadership.
Ratings
Consumer Reports Ratings:
Varies by model year and specific issues; consult historical Consumer Reports for detailed owner satisfaction and reliability ratings.
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