Chrysler Town & Country 2002 Workshop Repair Service Manual
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Basic Information Identification Make: Chrysler Model: Town & Country Year: 2002 Codes Platform: NS (Chrysler NS platform, shared with Dodge Grand Caravan and Plymouth Grand Voyager) Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals requiring spacious and versatile transportation. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Venture LS/Montana. Key Features Versatility: Known for flexible seating arrangements (e.g., Stow 'n Go, although not standard on all 2002 models, similar concepts existed) and spacious interior. Comfort: Designed for comfortable long-distance travel, often with a focus on family-oriented amenities. Powertrain Options: Offered with V6 engines providing adequate power for its size and load capacity. Manual Details Coverage Areas Covered Models: All 2002 Chrysler Town & Country models, All Engines, All Trims Page Count Estimated Page Count: Approximately 2000-3000 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, inspection, and repair for all available engines. Engine Electrical: Ignition system, starting system, charging system, fuel injection system diagnostics, ECU operation. Transmission: Automatic transmission overhaul (e.g., 41TE, 42LE), torque converter, shift controls, diagnostic procedures. Brakes: Hydraulic brake system, ABS diagnostics and repair, brake pad and rotor replacement, brake caliper service, parking brake. Suspension: Front and rear suspension components, shock absorbers, struts, ball joints, control arms, steering linkage. Steering: Power steering system, steering column, steering gear/rack and pinion, tie rod ends. HVAC: Air conditioning system service, heater core, blower motor, climate control operation, refrigerant handling. Electrical System: Lighting system, power windows, power locks, mirrors, wipers, horn, battery, fuses, relays. Body And Frame: Body panel repair, door mechanisms, latching systems, glass replacement, structural repair procedures. Interior: Seat removal and installation, interior trim panels, dashboard removal, center console. Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter replacement, evaporative emission control system (EVAP). Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, hanger replacement. Cooling System: Radiator, water pump, thermostat, coolant hoses, fan operation, coolant specifications. Diagnostic Trouble Codes: OBD-II diagnostic trouble code (DTC) definitions, troubleshooting charts, pinpoint tests. Procedures Included Routine Maintenance: Oil change, filter replacement, tire rotation, fluid level checks, spark plug replacement. Component Replacement: Detailed step-by-step instructions for replacing major and minor components across all systems. Troubleshooting Guides: Systematic approaches to diagnosing and resolving common and uncommon vehicle problems. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Torque Specifications: Precise torque values for all critical fasteners to ensure proper assembly and prevent damage. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle circuits. Schematics: System schematics for HVAC, fuel, braking, and other major systems. Technical Depth Depth: Comprehensive coverage from basic maintenance to in-depth engine and transmission rebuilds, including advanced diagnostics. Manual Specifications File Format File Type: PDF Searchability: Likely searchable text-based PDF, allowing for quick information retrieval. Print Quality Quality: Professional, clear text and diagrams suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Option 1: 3.3L (3301cc) OHV V6 (EGA/EGW) Horsepower 1: 180 hp @ 5000 rpm Torque 1: 205 lb-ft @ 3200 rpm Engine Option 2: 3.8L (3778cc) OHV V6 (L32/L36 - Less Common for 2002, more common in earlier years or specific trims) Horsepower 2: 200 hp @ 5000 rpm (for 3.8L) Torque 2: 230 lb-ft @ 3200 rpm (for 3.8L) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Engine Design Valvetrain: Overhead Valve (OHV) Block Material: Cast Iron Cylinder Head Material: Aluminum Transmission Standard Transmission Type: 4-speed Automatic Transaxle (e.g., 41TE/42LE) Optional Optional Transmission: N/A (Automatic was standard across the range for this generation) Features Transmission Fluid Spec: ATF+4 (Chrysler Mopar) Transmission Fluid Capacity: Approximately 7.7 quarts (7.3 liters) (refer to manual for exact capacity) Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 197.5 inches (5017 mm) Width: 76.8 inches (1951 mm) Height: 68.4 inches (1737 mm) Weights Curb Weight: Approximately 4,200 - 4,500 lbs (1905 - 2041 kg) depending on configuration. Towing Capacity: Up to 3,800 lbs (1724 kg) with optional towing package. Cargo Cargo Volume Behind 3Rd Row: Approx. 39.0 cu ft Cargo Volume Behind 2Nd Row: Approx. 100.0 cu ft Cargo Volume All Seats Folded: Approx. 160.0 cu ft Safety Features Ratings NHTSA Frontal Impact Driver: 4 Stars (for 2002 models) NHTSA Frontal Impact Passenger: 4 Stars (for 2002 models) NHTSA Side Impact Front Seat: 5 Stars (for 2002 models) NHTSA Side Impact Rear Seat: 5 Stars (for 2002 models) Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Traction Control: Optional Traction Control System (TCS) on some trims. Passive Features Airbags Front: Driver and front passenger airbags. Airbags Side: Optional front-seat side airbags on some trims. Seatbelts: Three-point seat...
Detailed step-by-step instructions for replacing major and minor components across all systems.
Troubleshooting Guides:
Systematic approaches to diagnosing and resolving common and uncommon vehicle problems.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Torque Specifications:
Precise torque values for all critical fasteners to ensure proper assembly and prevent damage.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle circuits.
Schematics:
System schematics for HVAC, fuel, braking, and other major systems.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to in-depth engine and transmission rebuilds, including advanced diagnostics.
Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text-based PDF, allowing for quick information retrieval.
Print Quality
Quality:
Professional, clear text and diagrams suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Option 1:
3.3L (3301cc) OHV V6 (EGA/EGW)
Horsepower 1:
180 hp @ 5000 rpm
Torque 1:
205 lb-ft @ 3200 rpm
Engine Option 2:
3.8L (3778cc) OHV V6 (L32/L36 - Less Common for 2002, more common in earlier years or specific trims)
Horsepower 2:
200 hp @ 5000 rpm (for 3.8L)
Torque 2:
230 lb-ft @ 3200 rpm (for 3.8L)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Engine Design
Valvetrain:
Overhead Valve (OHV)
Block Material:
Cast Iron
Cylinder Head Material:
Aluminum
Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle (e.g., 41TE/42LE)
Optional
Optional Transmission:
N/A (Automatic was standard across the range for this generation)
Features
Transmission Fluid Spec:
ATF+4 (Chrysler Mopar)
Transmission Fluid Capacity:
Approximately 7.7 quarts (7.3 liters) (refer to manual for exact capacity)
Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
197.5 inches (5017 mm)
Width:
76.8 inches (1951 mm)
Height:
68.4 inches (1737 mm)
Weights
Curb Weight:
Approximately 4,200 - 4,500 lbs (1905 - 2041 kg) depending on configuration.
Towing Capacity:
Up to 3,800 lbs (1724 kg) with optional towing package.
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 39.0 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 100.0 cu ft
Cargo Volume All Seats Folded:
Approx. 160.0 cu ft
Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars (for 2002 models)
NHTSA Frontal Impact Passenger:
4 Stars (for 2002 models)
NHTSA Side Impact Front Seat:
5 Stars (for 2002 models)
NHTSA Side Impact Rear Seat:
5 Stars (for 2002 models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Optional Traction Control System (TCS) on some trims.
Passive Features
Airbags Front:
Driver and front passenger airbags.
Airbags Side:
Optional front-seat side airbags on some trims.
Seatbelts:
Three-point seat belts for all occupants, LATCH child seat anchor system.
Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, cassette player, and optional premium sound systems. Some models featured rear-seat entertainment options.
Climate Control:
Manual or optional automatic climate control systems available.
Driver Assistance
Cruise Control:
Standard cruise control on most trims.
Parking Assistance:
Optional rear parking assist sensors available on some higher trims.
Connectivity
Connectivity Features:
Limited by modern standards; primarily focused on audio playback. No integrated Bluetooth or USB ports from factory.
Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Transmission Fluid Change:
Recommended every 30,000-60,000 miles (48,000-96,000 km) or as per severe service schedule. Use only ATF+4.
Coolant Change:
Initial change at 60,000 miles (96,000 km) or 5 years, then every 30,000 miles (48,000 km) or 3 years thereafter.
Spark Plug Replacement:
Typically around 100,000 miles (160,000 km) for the standard 3.3L V6 (using platinum or iridium plugs). Check manual for exact type and interval.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (synthetic blend or full synthetic recommended for better protection).
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) 50/50 mix, typically Mopar Antifreeze/Coolant (5 Year / 100,000 Mile Formula).
Power Steering Fluid:
ATF+4 (Chrysler Mopar)
Known Issues
Transmission Failure:
Early models of this generation were prone to transmission issues (slipping, overheating). Regular fluid changes with the correct type are critical.
Ignition Coil Failure:
Individual ignition coils can fail, leading to misfires and rough running. The manual will cover diagnostic procedures.
Power Sliding Door Issues:
Actuators, cables, and switches for power sliding doors can wear out or fail.
Heater Blower Motor:
Blower motor resistor or the motor itself can fail, leading to loss of climate control fan speed.
Oil Leaks:
Valve cover gaskets and oil pan gaskets can degrade over time and leak.
Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in the mid-1980s. The Town & Country served as the more upscale offering.
Model Evolution
Generation:
This 2002 model represents the third generation of the Chrysler minivan platform (NS), introduced for the 1996 model year and updated through subsequent years.
Production
Manufacturing Plant:
Windsor Assembly Plant, Windsor, Ontario, Canada.
Production Years Generation:
1996-2000 (first generation), 2001-2007 (second generation of this platform, which includes the 2002 model year).
Awards & Recognition
Recognitions
Wards Auto Ten Best Engines:
The 3.8L V6 engine (if equipped in some configurations) was a WardsAuto.com '10 Best Engines' winner in previous years, highlighting its robustness.
Ratings
Consumer Reports Reliability:
Reliability ratings for this era of Chrysler minivans were generally average to below average, particularly concerning the powertrain. The manual is essential for proper maintenance to mitigate issues.