Chrysler Voyager 2002 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Codes Platform Code: NS (for some markets), RS (North America) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, fleet operators, DIY mechanics, professional technicians. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager. Key Features Vehicle Appeal: Spacious interior, comfortable ride, flexible seating arrangements (Stow 'n Go became a significant feature in later iterations of the platform). Manual Value Proposition Utility: Essential resource for maintaining and repairing the Chrysler Voyager 2002, enabling cost savings for owners and providing accurate information for professionals. 📋 Manual Details Coverage Areas Engine Options Covered: 3.3L V6 (EGA), 3.8L V6 (L32) Transmission Options Covered: 41TE (Automatic), 42LE (Automatic) Trim Levels Covered: All trims (e.g., LX, EX, Limited, Stow 'n Go variations may be covered) Market Coverage: Primarily North America, with potential inclusion of international variants (e.g., European Voyager) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging, engine management (PCM/ECU) Transmission Systems: Automatic transmission (41TE/42LE) overhaul, diagnostics, shift control, fluid service Brake Systems: Front and rear brakes (disc/disc), ABS system operation, diagnostic procedures, component replacement Suspension And Steering: Front and rear suspension (struts, control arms, bushings, springs), power steering system, steering gear Electrical Systems: Battery, charging system, starting system, lighting, interior/exterior lights, power windows, locks, mirrors, power sliding door (if equipped), instrument cluster, body control module (BCM), wiring diagrams HVAC Systems: Heating, ventilation, air conditioning (A/C) system operation, diagnostics, refrigerant handling, component replacement Body And Interior: Body panels, doors, hinges, latches, interior trim, seating systems (including Stow 'n Go mechanism if applicable), glass replacement Procedures Included Maintenance Procedures: Routine maintenance (oil changes, filter replacements, spark plugs), inspections, lubrication Repair Procedures: Component removal and installation, rebuilding procedures for major components (engine, transmission), bodywork repairs Troubleshooting Procedures: System-specific diagnostic charts, symptom-based troubleshooting, fault code interpretation (OBD-II) Diagnostic Procedures: Step-by-step diagnostic sequences for electrical and mechanical issues, use of diagnostic tools Technical Depth Depth Of Coverage: Comprehensive: from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and body repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text content, allowing for quick information retrieval. Print Quality Print Quality: Professional; designed for clarity and readability when printed. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: EGA Engine Description 1: 3.3L OHV V6 Displacement 1: 3301 cc (201.5 cubic inches) Bore X Stroke 1: 96.0 mm x 76.0 mm (3.78 in x 2.99 in) Compression Ratio 1: 9.1:1 Horsepower 1: 158 hp @ 4500 rpm (SAE Net) Torque 1: 205 lb-ft @ 3400 rpm (SAE Net) Optional Engine Engine Code 2: L32 Engine Description 2: 3.8L OHV V6 (Supercharged option available on some later models, but less common for 2002 Voyager platform) Displacement 2: 3778 cc (230.5 cubic inches) Bore X Stroke 2: 96.0 mm x 84.0 mm (3.78 in x 3.31 in) Compression Ratio 2: 8.5:1 Horsepower 2: 180 hp @ 4400 rpm (SAE Net) Torque 2: 235 lb-ft @ 3400 rpm (SAE Net) Fuel System Fuel Delivery: Electronic Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended) Engine Management ECU Type: Chrysler's Powertrain Control Module (PCM) 🔧 Transmission Standard Transmission Type Standard: 4-Speed Automatic Transmission Model Standard: 41TE Optional Transmission Type Optional: 4-Speed Automatic Transmission Model Optional: 42LE (for 3.8L engine) Features Transmission Features: Electronically controlled, with overdrive, torque converter lock-up. 📐 Dimensions Exterior Wheelbase: Approx. 119.2 inches (3028 mm) Length: Approx. 187.5 inches (4763 mm) Width: Approx. 76.5 inches (1943 mm) Height: Approx. 67.9 inches (1725 mm) Weights Curb Weight Min: Approx. 4100 lbs (1860 kg) Gross Vehicle Weight Rating Gvw: Approx. 5750 lbs (2608 kg) 🛡️ Safety Features Ratings NHTSA Rollover Rating Driver Passenger: 4 of 5 stars Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Traction Control: Optional on some models. Passive Features Airbags Front: Standard driver and front passenger airbags. Airbags Side: Optional side-impact airbags, especially for front occupants. Seatbelts: Three-point seatbelts for all occupants, with pretensioners for front seats. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD or Cassette/CD player, optional Infinity or premium sound systems. Rear Seat Entertainment: Optional overhead video monitor and DVD player on some higher trims. Driver Assistance Cruise Control: Standard on most models. Parking Sensors: Optional rear parking assist system on some models. Connectivity Power Outlets: 12V auxiliary power outlets located in the cabin. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles (5,000-12,000 km) or 3-6 months, depending on driving conditions and oil type used (consult manual for...
Families, fleet operators, DIY mechanics, professional technicians.
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager.
Key Features
Vehicle Appeal:
Spacious interior, comfortable ride, flexible seating arrangements (Stow 'n Go became a significant feature in later iterations of the platform).
Manual Value Proposition
Utility:
Essential resource for maintaining and repairing the Chrysler Voyager 2002, enabling cost savings for owners and providing accurate information for professionals.
📋 Manual Details
Coverage Areas
Engine Options Covered:
3.3L V6 (EGA), 3.8L V6 (L32)
Transmission Options Covered:
41TE (Automatic), 42LE (Automatic)
Trim Levels Covered:
All trims (e.g., LX, EX, Limited, Stow 'n Go variations may be covered)
Market Coverage:
Primarily North America, with potential inclusion of international variants (e.g., European Voyager)
Automatic transmission (41TE/42LE) overhaul, diagnostics, shift control, fluid service
Brake Systems:
Front and rear brakes (disc/disc), ABS system operation, diagnostic procedures, component replacement
Suspension And Steering:
Front and rear suspension (struts, control arms, bushings, springs), power steering system, steering gear
Electrical Systems:
Battery, charging system, starting system, lighting, interior/exterior lights, power windows, locks, mirrors, power sliding door (if equipped), instrument cluster, body control module (BCM), wiring diagrams
HVAC Systems:
Heating, ventilation, air conditioning (A/C) system operation, diagnostics, refrigerant handling, component replacement
Body And Interior:
Body panels, doors, hinges, latches, interior trim, seating systems (including Stow 'n Go mechanism if applicable), glass replacement
Step-by-step diagnostic sequences for electrical and mechanical issues, use of diagnostic tools
Technical Depth
Depth Of Coverage:
Comprehensive: from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and body repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text content, allowing for quick information retrieval.
Print Quality
Print Quality:
Professional; designed for clarity and readability when printed.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA
Engine Description 1:
3.3L OHV V6
Displacement 1:
3301 cc (201.5 cubic inches)
Bore X Stroke 1:
96.0 mm x 76.0 mm (3.78 in x 2.99 in)
Compression Ratio 1:
9.1:1
Horsepower 1:
158 hp @ 4500 rpm (SAE Net)
Torque 1:
205 lb-ft @ 3400 rpm (SAE Net)
Optional Engine
Engine Code 2:
L32
Engine Description 2:
3.8L OHV V6 (Supercharged option available on some later models, but less common for 2002 Voyager platform)
Displacement 2:
3778 cc (230.5 cubic inches)
Bore X Stroke 2:
96.0 mm x 84.0 mm (3.78 in x 3.31 in)
Compression Ratio 2:
8.5:1
Horsepower 2:
180 hp @ 4400 rpm (SAE Net)
Torque 2:
235 lb-ft @ 3400 rpm (SAE Net)
Fuel System
Fuel Delivery:
Electronic Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Engine Management
ECU Type:
Chrysler's Powertrain Control Module (PCM)
🔧 Transmission
Standard
Transmission Type Standard:
4-Speed Automatic
Transmission Model Standard:
41TE
Optional
Transmission Type Optional:
4-Speed Automatic
Transmission Model Optional:
42LE (for 3.8L engine)
Features
Transmission Features:
Electronically controlled, with overdrive, torque converter lock-up.
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.2 inches (3028 mm)
Length:
Approx. 187.5 inches (4763 mm)
Width:
Approx. 76.5 inches (1943 mm)
Height:
Approx. 67.9 inches (1725 mm)
Weights
Curb Weight Min:
Approx. 4100 lbs (1860 kg)
Gross Vehicle Weight Rating Gvw:
Approx. 5750 lbs (2608 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating Driver Passenger:
4 of 5 stars
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Optional on some models.
Passive Features
Airbags Front:
Standard driver and front passenger airbags.
Airbags Side:
Optional side-impact airbags, especially for front occupants.
Seatbelts:
Three-point seatbelts for all occupants, with pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette/CD player, optional Infinity or premium sound systems.
Rear Seat Entertainment:
Optional overhead video monitor and DVD player on some higher trims.
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Optional rear parking assist system on some models.
Connectivity
Power Outlets:
12V auxiliary power outlets located in the cabin.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 3-6 months, depending on driving conditions and oil type used (consult manual for exact recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on inspection.
Spark Plug Replacement:
Typically every 60,000-100,000 miles (96,000-160,000 km) for platinum or iridium plugs (check specific plug type).
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), or per severe service schedule. Consult manual for specific fluid type (ATF+4 is common for Chrysler/Dodge).
Fluid Specifications
Engine Oil Spec:
API Service SG, SH, SJ or higher; SAE 5W-30 is commonly recommended for most climates. Check oil cap and manual.
Engine Oil Capacity:
Approx. 4.5 US quarts (4.3 liters) with filter for 3.3L; Approx. 5.0 US quarts (4.7 liters) with filter for 3.8L.
Coolant Spec:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, extended life, or equivalent.
Transmission Fluid Spec:
Chrysler ATF+4 (Automatic Transmission Fluid Type 9602).
Transmission Fluid Capacity:
Approx. 3.5 US quarts (3.3 liters) for dry fill, around 10-12 US quarts (9.5-11.3 liters) for a complete overhaul/flush.
Known Issues
Common Problems Engine:
Head gasket leaks, intake manifold gasket leaks, camshaft/crankshaft position sensor failures, oil filter adapter leaks, EGR valve issues.
Common Problems Transmission:
Torque converter shudder, solenoid pack failures, premature wear of clutches/bands, potential for overheating if transmission cooler is compromised.
Common Problems Electrical:
Faulty power window motors, HVAC blower motor resistor failures, intermittent dashboard warning lights, issues with the power sliding door mechanism.
Common Problems Suspension Steering:
Worn ball joints, tie rod ends, control arm bushings, and sway bar links leading to clunking noises and poor handling. Power steering pump leaks or noise.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation, later part of DaimlerChrysler.
Model Evolution
Generation:
Second Generation (RS/NS Platform)
Previous Generation Years:
1996-2000
Next Generation Years:
2008 onwards (for Chrysler Town & Country/Dodge Grand Caravan, as the Voyager nameplate was phased out for new generations in NA after 2003/2004, but continued in other markets).