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2002 Chrysler Town & Country Voyager Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Town & Country Model Variant: Voyager Model Variant Extended: Grand Voyager Production Year: 2002 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families seeking versatile transportation, fleet operators Competitive Analysis Key Competitors 2002: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza Key Features Convenience: Spacious interior, flexible seating arrangements, available power sliding doors, ample cargo space Reliability: Proven powertrain components (e.g., 3.3L V6), robust chassis design Versatility: Suitable for passenger transport, cargo hauling, and long-distance travel 📋 Manual Details Coverage Areas Regions: USA and Europe Page Count Estimated Pages: Over 1500 Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: 3.3L V6 (EGA), 3.8L V6 (L32) Transmission: 41TE (3-Speed Automatic), 42LE (4-Speed Automatic) Drivetrain: Front-Wheel Drive (FWD) Brakes: Front Disc, Rear Drum/Disc (ABS/TCS option) Suspension: Independent Front, Torsion Beam Rear Steering: Power Rack and Pinion Electrical: Complete wiring diagrams, charging system, starting system, lighting, instrumentation, comfort controls HVAC: Manual and Automatic Climate Control, Refrigerant system Body: Body panels, doors, windows, interior trim, seats, liftgate, power sliding doors Safety: Airbags, seat belts, child seat anchors Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, tune-ups, belt and hose inspection Diagnostics: On-board diagnostics (OBD-II) interpretation, DTC (Diagnostic Trouble Code) lookup, component testing Repair: Engine overhaul, transmission rebuilds, brake system repair, suspension component replacement, electrical system troubleshooting Assembly Disassembly: Detailed step-by-step instructions for component removal and installation Troubleshooting: Flowcharts and symptom-based troubleshooting guides Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission overhauls Detail Level: Includes torque specifications, clearances, diagnostic parameters, and wiring diagrams 📊 Manual Specifications File Format Digital Format: PDF Searchability: Text-searchable for quick information retrieval Print Quality Printability: High-resolution, suitable for printing specific sections or the entire manual Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EGA Engine Displacement 1: 3.3 Liters (3301 cc) Engine Configuration 1: 3.3L V6 (90 degree bank angle) Valve Train 1: Overhead Valve (OHV), 12 valves (2 per cylinder) Bore Stroke 1: 93.0 mm x 81.0 mm Compression Ratio 1: 8.9:1 Horsepower 1: 158 hp @ 4800 rpm Torque 1: 201 lb-ft @ 3600 rpm Optional Engine Engine Code 2: L32 Engine Displacement 2: 3.8 Liters (3778 cc) Engine Configuration 2: 3.8L V6 (90 degree bank angle) Valve Train 2: Overhead Valve (OHV), 12 valves (2 per cylinder) Bore Stroke 2: 96.0 mm x 87.0 mm Compression Ratio 2: 8.5:1 Horsepower 2: 180 hp @ 4500 rpm Torque 2: 235 lb-ft @ 3200 rpm Fuel System Fuel Type: Unleaded Gasoline Induction: Sequential Electronic Fuel Injection (SEFI) Fuel Pump Pressure: 31-45 PSI (214-310 kPa) 🔧 Transmission Standard Transmission Type 1: 41TE Automatic Transaxle Gears 1: 3-Speed Automatic Optional Transmission Type 2: 42LE Automatic Transaxle Gears 2: 4-Speed Automatic (with overdrive) Features Transmission Fluid Type: ATF+4 (Mopar) Transmission Fluid Capacity 41Te: 7.5 Quarts (7.1 Liters) Transmission Fluid Capacity 42Le: 7.5 Quarts (7.1 Liters) 📐 Dimensions Exterior Wheelbase Standard: 112.1 inches (2847 mm) Wheelbase Long: 119.3 inches (3030 mm) (Grand Voyager) Length Standard: 189.8 inches (4821 mm) Length Long: 196.9 inches (5001 mm) (Grand Voyager) Width: 76.0 inches (1930 mm) Height: 68.0 inches (1727 mm) Cargo Cargo Volume Behind 3Rd Row Standard: Approx. 37.0 cu ft (1047 Liters) Cargo Volume Behind 3Rd Row Long: Approx. 46.0 cu ft (1302 Liters) (Grand Voyager) Weights Curb Weight Min: Approx. 4,300 lbs (1950 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5,550 lbs (2517 kg) 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: ★★★★☆ (4/5 Stars) (Model dependent) NHTSA Frontal Passenger Rating: ★★★★☆ (4/5 Stars) (Model dependent) NHTSA Side Impact Driver Rating: ★★★★☆ (4/5 Stars) (Model dependent) NHTSA Side Impact Rear Passenger Rating: ★★★★☆ (4/5 Stars) (Model dependent) Active Features ABS: Standard Anti-lock Braking System (ABS) TCS: Optional Traction Control System (TCS) Passive Features Airbags: Driver and front passenger airbags, optional side airbags Seatbelts: 3-point seatbelts in all seating positions, front seatbelt pretensioners 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 Infinity sound system. Rear Seat Entertainment: Optional rear-seat video entertainment system (VES) with screen and headphone jacks. Driver Assistance Cruise Control: Standard electronic cruise control. Parking Assist: Optional rear parking assist sensors. Connectivity Remote Keyless Entry: Available on most trims. Power Accessories: Power windows, power door locks, power mirrors, power liftgate, power sliding doors (optional). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions (refer to owner's manual for specifics). Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) Spark Plug Replacement 3.3L: Platinum:...
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2002 Chrysler Town & Country Voyager Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Town & Country
Model Variant:
Voyager
Model Variant Extended:
Grand Voyager
Production Year:
2002
Codes
Platform:
NS (Third Generation)
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families seeking versatile transportation, fleet operators
Competitive Analysis
Key Competitors 2002:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza
Key Features
Convenience:
Spacious interior, flexible seating arrangements, available power sliding doors, ample cargo space
Reliability:
Proven powertrain components (e.g., 3.3L V6), robust chassis design
Versatility:
Suitable for passenger transport, cargo hauling, and long-distance travel
📋 Manual Details
Coverage Areas
Regions:
USA and Europe
Page Count
Estimated Pages:
Over 1500
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
3.3L V6 (EGA), 3.8L V6 (L32)
Transmission:
41TE (3-Speed Automatic), 42LE (4-Speed Automatic)
Drivetrain:
Front-Wheel Drive (FWD)
Brakes:
Front Disc, Rear Drum/Disc (ABS/TCS option)
Suspension:
Independent Front, Torsion Beam Rear
Steering:
Power Rack and Pinion
Electrical:
Complete wiring diagrams, charging system, starting system, lighting, instrumentation, comfort controls
HVAC:
Manual and Automatic Climate Control, Refrigerant system
Body:
Body panels, doors, windows, interior trim, seats, liftgate, power sliding doors
Safety:
Airbags, seat belts, child seat anchors
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, tune-ups, belt and hose inspection
Diagnostics:
On-board diagnostics (OBD-II) interpretation, DTC (Diagnostic Trouble Code) lookup, component testing
Repair:
Engine overhaul, transmission rebuilds, brake system repair, suspension component replacement, electrical system troubleshooting
Assembly Disassembly:
Detailed step-by-step instructions for component removal and installation
Troubleshooting:
Flowcharts and symptom-based troubleshooting guides
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls
Detail Level:
Includes torque specifications, clearances, diagnostic parameters, and wiring diagrams
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Printability:
High-resolution, suitable for printing specific sections or the entire manual
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA
Engine Displacement 1:
3.3 Liters (3301 cc)
Engine Configuration 1:
3.3L V6 (90 degree bank angle)
Valve Train 1:
Overhead Valve (OHV), 12 valves (2 per cylinder)
Bore Stroke 1:
93.0 mm x 81.0 mm
Compression Ratio 1:
8.9:1
Horsepower 1:
158 hp @ 4800 rpm
Torque 1:
201 lb-ft @ 3600 rpm
Optional Engine
Engine Code 2:
L32
Engine Displacement 2:
3.8 Liters (3778 cc)
Engine Configuration 2:
3.8L V6 (90 degree bank angle)
Valve Train 2:
Overhead Valve (OHV), 12 valves (2 per cylinder)
Bore Stroke 2:
96.0 mm x 87.0 mm
Compression Ratio 2:
8.5:1
Horsepower 2:
180 hp @ 4500 rpm
Torque 2:
235 lb-ft @ 3200 rpm
Fuel System
Fuel Type:
Unleaded Gasoline
Induction:
Sequential Electronic Fuel Injection (SEFI)
Fuel Pump Pressure:
31-45 PSI (214-310 kPa)
🔧 Transmission
Standard
Transmission Type 1:
41TE Automatic Transaxle
Gears 1:
3-Speed Automatic
Optional
Transmission Type 2:
42LE Automatic Transaxle
Gears 2:
4-Speed Automatic (with overdrive)
Features
Transmission Fluid Type:
ATF+4 (Mopar)
Transmission Fluid Capacity 41Te:
7.5 Quarts (7.1 Liters)
Transmission Fluid Capacity 42Le:
7.5 Quarts (7.1 Liters)
📐 Dimensions
Exterior
Wheelbase Standard:
112.1 inches (2847 mm)
Wheelbase Long:
119.3 inches (3030 mm) (Grand Voyager)
Length Standard:
189.8 inches (4821 mm)
Length Long:
196.9 inches (5001 mm) (Grand Voyager)
Width:
76.0 inches (1930 mm)
Height:
68.0 inches (1727 mm)
Cargo
Cargo Volume Behind 3Rd Row Standard:
Approx. 37.0 cu ft (1047 Liters)
Cargo Volume Behind 3Rd Row Long:
Approx. 46.0 cu ft (1302 Liters) (Grand Voyager)
Weights
Curb Weight Min:
Approx. 4,300 lbs (1950 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5,550 lbs (2517 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Rating:
★★★★☆ (4/5 Stars) (Model dependent)
NHTSA Frontal Passenger Rating:
★★★★☆ (4/5 Stars) (Model dependent)
NHTSA Side Impact Driver Rating:
★★★★☆ (4/5 Stars) (Model dependent)
NHTSA Side Impact Rear Passenger Rating:
★★★★☆ (4/5 Stars) (Model dependent)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
TCS:
Optional Traction Control System (TCS)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point seatbelts in all seating positions, front seatbelt pretensioners
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 Infinity sound system.
Rear Seat Entertainment:
Optional rear-seat video entertainment system (VES) with screen and headphone jacks.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Assist:
Optional rear parking assist sensors.
Connectivity
Remote Keyless Entry:
Available on most trims.
Power Accessories:
Power windows, power door locks, power mirrors, power liftgate, power sliding doors (optional).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions (refer to owner's manual for specifics).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km)
Spark Plug Replacement 3.3L:
Platinum: 100,000 miles; Standard: 30,000 miles
Spark Plug Replacement 3.8L:
Platinum: 100,000 miles; Standard: 30,000 miles
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 2 years
Fluid Specifications
Engine Oil Type 3.3L:
SAE 5W-30 (API SN or higher)
Engine Oil Type 3.8L:
SAE 5W-30 (API SN or higher)
Engine Oil Capacity 3.3L:
4.0 Quarts (3.8 Liters) with filter
Engine Oil Capacity 3.8L:
4.5 Quarts (4.3 Liters) with filter
Coolant Type:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (Blue)
Power Steering Fluid:
ATF+4 (Mopar)
Brake Fluid Type:
DOT 3
Known Issues
Common Problems Powertrain:
Occasional transmission solenoid issues, potential for head gasket leaks on higher mileage 3.3L engines, timing chain wear on 3.8L.
Common Problems Electrical:
Power window motor failures, intermittent issues with power sliding door mechanisms, dashboard illumination faults.
Common Problems Suspension:
Worn control arm bushings, failing front struts/shocks, ball joint wear.
Common Problems HVAC:
Blend door actuator failures leading to temperature control issues, refrigerant leaks.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1984, establishing the benchmark for family vehicles.
Model Evolution
Generation Ns:
The 2001-2007 generation (NS) represented a significant redesign, featuring a more aerodynamic shape, improved interior comfort and features, and enhanced safety.
Design Language:
This generation adopted a smoother, more rounded aesthetic compared to its predecessors.
Production
Assembly Locations:
Windsor, Ontario, Canada (Chrysler Canada Inc.)
Production Run Ns Generation:
2001-2007
🏆 Awards & Recognition
Recognitions
Car And Driver 5 Best Trucks:
The Town & Country and its platform siblings often featured on Car and Driver's '5 Best Trucks' list in its early years, recognizing their minivan segment leadership.
Consumers Digest Best Buy:
Chrysler minivans frequently received 'Best Buy' ratings from publications like Consumer's Digest for their value and features.
Certifications
Safety Certifications:
Compliant with all US Federal Motor Vehicle Safety Standards (FMVSS) for 2002 model year.
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