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Chrysler Grand Voyager 2002-2004 Factory Service Repair Manual

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Welcome to the comprehensive service manual for the Chrysler Grand Voyager, covering model years 2002, 2003, and 2004. This minivan, built on the NS/GS platform, is renowned for its pioneering...
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Tipo: Car
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SKU: 104540
Chrysler Grand Voyager 2002-2004 Factory Service Repair Manual
Welcome to the comprehensive service manual for the Chrysler Grand Voyager, covering model years 2002, 2003, and 2004. This minivan, built on the NS/GS platform, is renowned for its pioneering role in the minivan segment and offers spacious interiors typically seating seven or eight passengers, making it an ideal choice for families and long-distance travel. Key features include multi-point fuel injection, a 4-speed automatic transaxle, and available technologies such as rear-seat entertainment systems and power sliding doors. Its engineering prioritizes reliability and practicality, with a strong heritage rooted in Chrysler's innovation in the automotive industry. This factory service repair manual provides in-depth information essential for maintaining and repairing your Chrysler Grand Voyager. Its extensive coverage includes detailed procedures for powertrain systems such as the engine, transmission, fuel, and emission controls, as well as chassis and suspension components including brakes, steering, and body. The manual also details electrical systems, HVAC, and safety features like airbags and seatbelts. With step-by-step repair instructions, diagnostic guides, troubleshooting tips, and comprehensive technical specifications, this English-language resource empowers DIY owners and professional technicians alike to ensure optimal performance and longevity of the vehicle.
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Grand Voyager
Years:
2002, 2003, 2004
Codes
Platform:
NS/GS (2nd Generation)
👋 Introduction
Market Position
Target Audience:
DIY owners, professional technicians, and repair shops
Competitive Analysis
Advantage:
Official factory information, comprehensive coverage, downloadable format, cost savings on labor
Key Features
Features:
Hundreds of pages, all styles covered, genuine factory manual, detailed illustrations, diagrams, specifications, troubleshooting guide, step-by-step instructions, printable
📋 Manual Details
Coverage Areas
Regions:
Global (North America, Europe, etc.)
Page Count
Estimated Pages:
Hundreds (Specific count not provided, but described as comprehensive)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Service/Repair, Transmission Service/Repair, Fuel Injection/Fuel System, Emission System, Engine Control System, Differential/Drive, Axle
Chassis And Suspension:
Brake System, Suspension, Steering, Chassis/Body
Electrical And Comfort:
Wiring Diagram, Electrical System, Cooling System, Heater/Air Conditioner, Restraint System (Airbags/Seatbelts), Interior
Procedures Included
Maintenance:
General Maintenance, Periodic Lubrication
Diagnostics And Repair:
Troubleshooting, Step-by-step repair procedures, Diagnostic guides
Technical Depth
Depth:
Comprehensive; covers fundamental to advanced repair, maintenance, rebuilding, refurbishing, and restoration
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable without restriction (entire manual or selected pages)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirements
Reader:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely 3.3L (e.g., EGQ) and 3.8L (e.g., EGH) V6 engines. Specific codes and variations would be detailed within the manual.
Performance
Horsepower Torque:
Varies by engine. For context, the 3.3L typically produced around 180 hp and 210 lb-ft, while the 3.8L offered approximately 200-205 hp and 230-235 lb-ft. Exact figures require consulting the manual.
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Type:
Likely 4-speed automatic transaxle (e.g., 41TE, 42LE). Specific identification and internal components detailed in manual.
Optional
Transmission Options:
No manual transmission offered for Grand Voyager in these years.
Features
Transmission Features:
Electronic controls, torque converter lock-up
📐 Dimensions
Exterior
Body Style:
Minivan
Interior
Seating Capacity:
Typically 7 or 8 passengers, with various seating configurations.
Weights
Curb Weight:
Approximately 4,100 - 4,400 lbs (1860 - 2000 kg), depending on configuration.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by year and specific test, but generally good for its class. Frontal crash test ratings were often 4 or 5 stars. Side impact ratings should be checked for specific years.
Active Features
Active Safety:
Anti-lock Braking System (ABS), Traction Control (ASR/TCS) on some models
Passive Features
Passive Safety:
Front airbags, front side airbags (optional/later years), three-point seatbelts for all occupants, LATCH child seat anchors
💡 Technology Features
Infotainment
Audio Systems:
Various radio options including AM/FM, CD players, and optional premium Infinity sound systems. Cassette players were also common.
Entertainment Options:
Optional rear-seat entertainment system (TV/VCR or DVD player) on higher trims.
Driver Assistance
Convenience Features:
Power sliding doors, power liftgate (optional), remote keyless entry, cruise control, tilt steering wheel.
Connectivity
Connectivity Options:
Limited by modern standards. Likely no Bluetooth or USB connectivity. Auxiliary input for audio may be present on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles (5,000-8,000 km) under normal driving conditions. Consult manual for Severe Duty schedule and synthetic oil recommendations.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grade (e.g., SAE 5W-30) and API service classification.
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification. Manual will confirm exact type and capacity).
Coolant Type:
Chrysler's long-life OAT coolant (Orange) or HOAT (Hybrid OAT) type. Manual will specify the exact Mopar part number or equivalent.
Known Issues
Common Problems:
Transmission issues (e.g., solenoid pack failure, torque converter shudder), EGR valve clogging, power window motor failure, rear suspension sag, potential head gasket issues on earlier 3.8L engines (though less common on 2002+ models).
📚 Vehicle History
Brand Heritage
Brand Origin:
Chrysler Corporation, known for pioneering the minivan segment with the original Dodge Caravan/Plymouth Voyager.
Model Evolution
Generation:
This falls into the second generation (NS/GS) of the Chrysler minivan platform, which saw significant updates over its predecessor.
Production
Manufacturing Location:
Primarily Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Chrysler Voyager/Grand Voyager platform was a frequent recipient of Car and Driver's '10Best' awards in its earlier generations, establishing its benchmark status in the minivan segment. While specific year awards for 2002-2004 would need verification, the platform's reputation was strong.
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