🏷️ Basic Information

Make:

Chrysler

Model:

Voyager

Year:

2002

Market:

North America (and potentially other markets where Voyager was sold)

Platform Code:

NS (Third Generation)

👋 Introduction

Segment:

Minivan, family vehicle.

Competitors 2002:

Ford Windstar, Chevrolet Venture/Montana, Pontiac Montana, Oldsmobile Silhouette, Buick Terraza, Honda Odyssey, Toyota Sienna.

Vehicle Focus:

Spacious interior, versatile seating, family-oriented features, comfortable ride.

Value Proposition:

Empowers DIY enthusiasts and professional mechanics with the detailed knowledge required for accurate diagnosis and repair, ensuring vehicle longevity and optimal performance.

📋 Manual Details

Covered Regions:

All mechanical and electrical systems, bodywork, diagnostics, troubleshooting, maintenance, and repair for the 2002 Chrysler Voyager.

Estimated Page Count:

Over 1000 pages (typical for a comprehensive factory-style service manual)

Type:

Service and Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed information on all engine variants including diagnosis, repair, and overhaul for 2.4L I4 and 3.3L V6 engines.

Transmission:

Coverage for automatic transmissions (e.g., 41TE, 42LE), including diagnostics, fluid changes, seal replacement, and internal repairs.

Brakes:

Front and rear brake systems, ABS (Anti-lock Braking System) diagnosis and repair, rotor/pad replacement, caliper service.

Suspension:

Front and rear suspension components, steering system, wheel alignment specifications, shock absorber/strut replacement.

Electrical:

Complete electrical schematics, wiring diagrams, component testing, diagnosis of lighting, power accessories, charging system, starting system, body control modules.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, refrigerant handling, component replacement, blower motor, climate control units.

Body:

Body panel repair, door mechanisms, power sliding doors, interior trim removal/installation, glass replacement.

Fuel System:

Fuel pump diagnosis, fuel injectors, fuel filter replacement, evaporative emissions (EVAP) system.

Cooling System:

Radiator, water pump, thermostat, cooling fan operation, coolant specifications and flush procedures.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, emissions control components.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, tire rotation, fluid level checks and top-offs.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common drivability and electrical issues.

Repair Procedures:

Step-by-step repair instructions for virtually all vehicle components, from simple bulb replacement to complex engine or transmission overhauls.

Component Replacement:

Detailed guidance for replacing major components like alternators, starters, fuel pumps, water pumps, radiators, etc.

Diagnostics:

Information on using diagnostic trouble codes (DTCs), scan tools, and electrical testing equipment.

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including advanced diagnostic procedures and torque specifications.

📊 Manual Specifications

File Type:

PDF

Searchability:

Text-searchable PDF for quick information retrieval.

Quality:

High-resolution scans for clear diagrams and text.

Binding:

N/A (Digital Download - PDF)

Paper:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Engine 1:

2.4L (2426cc) DOHC Inline 4-cylinder (GEMA engine family)

Engine 2:

3.3L (3301cc) OHV V6 (EGA engine family)

Horsepower 2.4L:

Approx. 150 hp @ 5200 rpm

Torque 2.4L:

Approx. 167 lb-ft @ 4000 rpm

Horsepower 3.3L:

Approx. 180 hp @ 5000 rpm

Torque 3.3L:

Approx. 205 lb-ft @ 3600 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI)

Engine Codes:

Refer to manual for specific engine codes tied to VIN or engine build date.

🔧 Transmission

Transmission Type Standard:

4-speed Automatic

Transmission Type Optional:

N/A (Automatic was standard for this generation and model year)

Transmission Models:

41TE (for 2.4L I4) and 42LE (for 3.3L V6) variations.

Transmission Fluid Type:

ATF+4 (Chrysler Material Standard MS-9602)

Transmission Fluid Capacity:

Approx. 4.0 quarts (3.8 liters) for a pan drop and fill. Refer to manual for complete overhaul capacity.

📐 Dimensions

Wheelbase:

Approx. 119.3 inches (3030 mm)

Length:

Approx. 191.3 inches (4859 mm)

Width:

Approx. 76.5 inches (1943 mm)

Height:

Approx. 67.8 inches (1722 mm)

Seating Capacity:

7-8 passengers (depending on configuration)

Cargo Volume Behind 3Rd Row:

Approx. 38.1 cubic feet

Cargo Volume Max:

Approx. 146.5 cubic feet (with all rear seats removed)

Curb Weight 2.4L:

Approx. 4000 - 4200 lbs (1814 - 1905 kg)

Curb Weight 3.3L:

Approx. 4100 - 4300 lbs (1860 - 1950 kg)

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (for 2002 model)

NHTSA Front Impact Passenger:

4 Stars (for 2002 model)

IIHS Side Impact:

Acceptable (for 2002 model)

ABS:

Standard (Anti-lock Braking System)

Traction Control:

Optional on some trims.

Airbags Front:

Driver and front passenger airbags.

Airbags Side:

Optional front-seat side airbags on some trims.

Seatbelts:

All seating positions equipped with three-point seatbelts; front seatbelt pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM/CD or cassette player. Optional Infinity speaker systems.

Rear Entertainment:

Optional rear-seat entertainment system (VES - Video Entertainment System) with overhead screen and headphone jacks available on some trims.

Cruise Control:

Standard on most trims.

Keyless Entry:

Optional remote keyless entry system.

Power Sliding Door:

Optional power sliding rear passenger doors.

Power Liftgate:

Not typically available on this generation. Manual liftgate.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles (4,800-12,000 km) or 3-6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Transmission Fluid Change Interval:

Every 30,000-100,000 miles (48,000-160,000 km) or 2-5 years, depending on driving conditions (severe vs. normal). Refer to manual for specific guidance.

Spark Plug Replacement Interval 4Cyl:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Spark Plug Replacement Interval V6:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Engine Oil Type:

SAE 5W-30 (API Certified, meeting MS-6395 specification).

Coolant Type:

Chrysler Long Life Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), color may vary (often orange or pink). Mix 50/50 with distilled water.

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 (check manual for confirmation, often ATF or specific power steering fluid)

Common Issue 1:

Transmission solenoid pack failures leading to shifting problems or no-reverse conditions.

Common Issue 2:

Water pump seal leaks or bearing failure.

Common Issue 3:

CV joint wear and failure, particularly on front axles.

Common Issue 4:

Cooling fan motor failure or relay issues.

Common Issue 5:

Power window motor or regulator failures.

Common Issue 6:

Exhaust system corrosion and rust.

Preventative Maintenance:

Crucial for understanding proactive maintenance schedules to avoid common failures and extend vehicle life.

📚 Vehicle History

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. The Voyager nameplate has been synonymous with family transport for decades.

Generation:

Third Generation (NS) minivan platform, introduced for the 1996 model year and updated through 2000.

Production Years Ns:

1996-2000 (although the 2001 model year saw a significant facelift and platform designation change to RS for subsequent years, this manual specifically covers the pre-facelift 2002 model which retained much of the NS architecture).

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant).

🏆 Awards & Recognition

Minivan Accolades:

Chrysler minivans consistently received praise for their interior packaging and versatility in period reviews. Specific awards for the 2002 Voyager model are less prominent than industry-wide recognition for the segment.

Car And Driver Ratings:

Chrysler minivans were often featured in Car and Driver's '10Best' lists in earlier years, establishing their competitive edge.