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2002 Dodge Intrepid Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Intrepid Year: 2002 Codes Chassis Code: LH 👋 Introduction Market Position Segment: Full-size sedan Target Audience: Families, commuters seeking space and comfort Competitive Analysis Key Competitors: Ford Taurus, Chevrolet Impala, Toyota Avalon, Buick LeSabre Key Features Platform: Chrysler LH platform, shared with Chrysler Concorde/LHS and Eagle Vision. Design: Distinctive cab-forward design, aerodynamic styling. Interior: Spacious interior, comfortable seating, available premium features. 📋 Manual Details Coverage Areas Primary Coverage: All models and all repairs A-Z Specificity: Vehicle specific, not generic repair information Target User: Dealership technicians Page Count Estimated Page Count: 1500+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Print 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for all gasoline engines, including timing, lubrication, cooling, and fuel delivery. Engine Electrical: Detailed wiring diagrams, ECU diagnostics, sensor testing, ignition system analysis, and starting/charging systems. Transmission Automatic: Diagnosis, repair, overhaul, and fluid specifications for the 42LE automatic transmission. Transmission Manual: While less common, manual transmission repair and component identification if applicable to specific trims. Brakes: ABS diagnostics, hydraulic system repair, brake pad/rotor replacement, caliper servicing, and parking brake adjustments. Suspension: Strut and shock absorber replacement, spring servicing, control arm and ball joint inspection, wheel bearing replacement, and alignment specifications. Steering: Power steering system diagnosis, pump and rack replacement, tie rod end servicing, and steering column adjustments. Electrical Body: Power windows, locks, mirrors, lighting (headlights, taillights, interior), horn, wipers, and related switchgear. HVAC: Climate control system diagnosis, refrigerant handling, compressor, condenser, evaporator servicing, and blower motor replacement. Body And Chassis: Body panel removal/installation, door and latch mechanisms, interior trim, glass replacement, and chassis component identification. Diagnostics: OBD-II diagnostic trouble codes (DTCs), scan tool procedures, and symptom-based troubleshooting guides. Procedures Included Maintenance: Routine oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, and belt inspections. Troubleshooting: Systematic diagnostic routines for common and uncommon drivability issues, electrical faults, and mechanical problems. Repair: Step-by-step instructions for component replacement, system overhauls, and part-specific repairs. Specifications: Torque specifications for all fasteners, fluid capacities, diagnostic parameter values, and component tolerances. Wiring Diagrams: Comprehensive electrical schematics for all major vehicle systems. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Diagnostic Focus: In-depth diagnostic procedures, including component testing and likely fault identification. Special Tools: Identification of any special tools required for specific procedures. 📊 Manual Specifications File Format Digital Format If Applicable: N/A (Print Manual) Print Quality Print Quality: High-quality, professional printing Binding Type Binding: Durable binding (e.g., spiral-bound, perfect-bound) for ease of use in a workshop environment. Paper Type Paper Type: Durable, potentially coated paper to resist shop grease and fluids. ⚙️ Engine Specifications Primary Engine Engine 1: 2.7L V6 SOHC Engine 1 Displacement: 2736 cc Engine 1 Horsepower: 200 hp @ 5800 rpm Engine 1 Torque: 190 lb-ft @ 4500 rpm Engine 2: 3.2L V6 SOHC Engine 2 Displacement: 3231 cc Engine 2 Horsepower: 225 hp @ 6300 rpm Engine 2 Torque: 225 lb-ft @ 4700 rpm Engine 3: 3.5L V6 SOHC (ES/ES Plus/GT trims) Engine 3 Displacement: 3518 cc Engine 3 Horsepower: 234 hp @ 6000 rpm Engine 3 Torque: 241 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 octane (89 recommended for 3.2L and 3.5L for optimal performance) Performance 0 60 Mph Approx: 7.5 - 9.0 seconds (depending on engine) 🔧 Transmission Standard Transmission Type: 4-speed automatic (42LE) Optional Optional Transmission: N/A (Automatic only for 2002) Features Transmission Features: Electronically controlled, overdrive, performance shifting modes (on some trims). Fluid Specifications Transmission Fluid Type: ATF+4 (MS-9602) Fluid Capacity Transmission Fluid Capacity: Approximately 4.5 US quarts (dry fill), 10.5 US quarts (total capacity). 📐 Dimensions Exterior Length: 200.0 inches Width: 74.4 inches Height: 56.9 inches Wheelbase: 113.0 inches Interior Passenger Volume: 105.0 cubic feet Cargo Trunk Volume: 16.1 cubic feet Weights Curb Weight Est: 3500 - 3700 lbs (depending on engine and trim) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver), 4/5 Stars (Passenger) NHTSA Side Impact: N/A (Not tested extensively for this year) Active Features Traction Control: Available on some trims ABS: Standard on all models Passive Features Airbags Front: Standard advanced multi-stage front airbags Airbags Side: Available optional front side airbags Seatbelts: 3-point seatbelts with pretensioners and load limiters 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player, cassette player, and optional premium Infinity sound system with amplifier and subwoofer. Climate Control: Manual climate control or optional automatic climate control (ACC) with digital display and dual-zone capability. Driver Assistance Cruise Control: Standard on most trims. Keyless Entry: Available keyless entry system with remote fob. Connectivity Phone Integration: N/A (No factory Bluetooth or smartphone integration in this era). 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months,...
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2002 Dodge Intrepid Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Intrepid
Year:
2002
Codes
Chassis Code:
LH
👋 Introduction
Market Position
Segment:
Full-size sedan
Target Audience:
Families, commuters seeking space and comfort
Competitive Analysis
Key Competitors:
Ford Taurus, Chevrolet Impala, Toyota Avalon, Buick LeSabre
Key Features
Platform:
Chrysler LH platform, shared with Chrysler Concorde/LHS and Eagle Vision.
Design:
Distinctive cab-forward design, aerodynamic styling.
Interior:
Spacious interior, comfortable seating, available premium features.
📋 Manual Details
Coverage Areas
Primary Coverage:
All models and all repairs A-Z
Specificity:
Vehicle specific, not generic repair information
Target User:
Dealership technicians
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Print
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures for all gasoline engines, including timing, lubrication, cooling, and fuel delivery.
Engine Electrical:
Detailed wiring diagrams, ECU diagnostics, sensor testing, ignition system analysis, and starting/charging systems.
Transmission Automatic:
Diagnosis, repair, overhaul, and fluid specifications for the 42LE automatic transmission.
Transmission Manual:
While less common, manual transmission repair and component identification if applicable to specific trims.
Brakes:
ABS diagnostics, hydraulic system repair, brake pad/rotor replacement, caliper servicing, and parking brake adjustments.
Suspension:
Strut and shock absorber replacement, spring servicing, control arm and ball joint inspection, wheel bearing replacement, and alignment specifications.
Steering:
Power steering system diagnosis, pump and rack replacement, tie rod end servicing, and steering column adjustments.
Electrical Body:
Power windows, locks, mirrors, lighting (headlights, taillights, interior), horn, wipers, and related switchgear.
HVAC:
Climate control system diagnosis, refrigerant handling, compressor, condenser, evaporator servicing, and blower motor replacement.
Body And Chassis:
Body panel removal/installation, door and latch mechanisms, interior trim, glass replacement, and chassis component identification.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), scan tool procedures, and symptom-based troubleshooting guides.
Procedures Included
Maintenance:
Routine oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, and belt inspections.
Troubleshooting:
Systematic diagnostic routines for common and uncommon drivability issues, electrical faults, and mechanical problems.
Repair:
Step-by-step instructions for component replacement, system overhauls, and part-specific repairs.
Specifications:
Torque specifications for all fasteners, fluid capacities, diagnostic parameter values, and component tolerances.
Wiring Diagrams:
Comprehensive electrical schematics for all major vehicle systems.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Focus:
In-depth diagnostic procedures, including component testing and likely fault identification.
Special Tools:
Identification of any special tools required for specific procedures.
📊 Manual Specifications
File Format
Digital Format If Applicable:
N/A (Print Manual)
Print Quality
Print Quality:
High-quality, professional printing
Binding Type
Binding:
Durable binding (e.g., spiral-bound, perfect-bound) for ease of use in a workshop environment.
Paper Type
Paper Type:
Durable, potentially coated paper to resist shop grease and fluids.
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.7L V6 SOHC
Engine 1 Displacement:
2736 cc
Engine 1 Horsepower:
200 hp @ 5800 rpm
Engine 1 Torque:
190 lb-ft @ 4500 rpm
Engine 2:
3.2L V6 SOHC
Engine 2 Displacement:
3231 cc
Engine 2 Horsepower:
225 hp @ 6300 rpm
Engine 2 Torque:
225 lb-ft @ 4700 rpm
Engine 3:
3.5L V6 SOHC (ES/ES Plus/GT trims)
Engine 3 Displacement:
3518 cc
Engine 3 Horsepower:
234 hp @ 6000 rpm
Engine 3 Torque:
241 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 octane (89 recommended for 3.2L and 3.5L for optimal performance)
Performance
0 60 Mph Approx:
7.5 - 9.0 seconds (depending on engine)
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (42LE)
Optional
Optional Transmission:
N/A (Automatic only for 2002)
Features
Transmission Features:
Electronically controlled, overdrive, performance shifting modes (on some trims).
Fluid Specifications
Transmission Fluid Type:
ATF+4 (MS-9602)
Fluid Capacity
Transmission Fluid Capacity:
Approximately 4.5 US quarts (dry fill), 10.5 US quarts (total capacity).
📐 Dimensions
Exterior
Length:
200.0 inches
Width:
74.4 inches
Height:
56.9 inches
Wheelbase:
113.0 inches
Interior
Passenger Volume:
105.0 cubic feet
Cargo
Trunk Volume:
16.1 cubic feet
Weights
Curb Weight Est:
3500 - 3700 lbs (depending on engine and trim)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver), 4/5 Stars (Passenger)
NHTSA Side Impact:
N/A (Not tested extensively for this year)
Active Features
Traction Control:
Available on some trims
ABS:
Standard on all models
Passive Features
Airbags Front:
Standard advanced multi-stage front airbags
Airbags Side:
Available optional front side airbags
Seatbelts:
3-point seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player, cassette player, and optional premium Infinity sound system with amplifier and subwoofer.
Climate Control:
Manual climate control or optional automatic climate control (ACC) with digital display and dual-zone capability.
Driver Assistance
Cruise Control:
Standard on most trims.
Keyless Entry:
Available keyless entry system with remote fob.
Connectivity
Phone Integration:
N/A (No factory Bluetooth or smartphone integration in this era).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (synthetic oil recommended).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed.
Cabin Air Filter:
Inspect every 15,000 miles, replace as needed.
Spark Plugs:
Replace every 100,000 miles (platinum tipped).
Transmission Fluid Change:
Inspect every 30,000 miles, change every 60,000 miles or as indicated by fluid condition.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Certified)
Engine Oil Capacity:
4.5 US quarts (with filter) for 2.7L and 3.2L; 5.0 US quarts (with filter) for 3.5L.
Coolant Type:
Mopar Antifreeze/Coolant (ethylene glycol based) or equivalent meeting MS-7170 specification (typically a green coolant).
Coolant Capacity:
Approximately 12.5 US quarts (depending on engine).
Brake Fluid Type:
DOT 3
Power Steering Fluid:
Mopar Power Steering Fluid or ATF+4
Known Issues
Common Issue 1:
Head gasket leaks (particularly on 2.7L V6 engine).
Common Issue 2:
Transmission solenoid issues or failure in the 42LE automatic transmission.
Common Issue 3:
Front suspension component wear (e.g., ball joints, control arm bushings).
Common Issue 4:
Water pump leaks, especially around the gasket.
Common Issue 5:
Evaporator core leaks in the HVAC system, leading to poor cooling and a musty smell.
📚 Vehicle History
Brand Heritage
Dodge Heritage:
Dodge, a division of Chrysler Corporation (later DaimlerChrysler), has a long history of producing American cars with a focus on performance and value.
Model Evolution
Intrepid Lineage:
The Intrepid nameplate was reintroduced for the 1993 model year on the first-generation LH platform. The 2002 model represents the second generation of the LH Intrepid, introduced for the 1998 model year.
2002 Updates:
For 2002, the Intrepid received minor updates, including revised front and rear fascia styling, updated wheel designs, and interior trim enhancements. The 3.5L engine became more widely available across trims.
Production
Manufacturing Location:
Bramalea, Ontario, Canada
Production Years:
1993-2004
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
While the 2002 model year didn't receive specific major awards, the Intrepid as part of the LH platform was recognized for its styling and spaciousness in its debut years.
Ratings
Consumer Reports:
Consumer Reports ratings for the 2002 Intrepid generally placed it in the average to below-average category for reliability, particularly concerning the 2.7L engine and transmission.
Certifications
Emission Standards:
Meets EPA and CARB emission standards for the model year.
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