🏷️ Basic Information

Make:

Chrysler

Model:

Voyager

Year:

2002

Platform:

NS/RS

👋 Introduction

Vehicle Segment:

Full-size Minivan

Target Audience:

Families, commercial use, fleet operators

Key Competitors:

Dodge Grand Caravan, Ford Windstar, Honda Odyssey, Toyota Sienna

Interior Versatility:

Flexible seating arrangements, ample cargo space, Stow 'n Go (later models, but design philosophy present)

Powertrain Options:

Reliable V6 engines known for torque and towing capacity

Ride Comfort:

Tuned for comfortable long-distance cruising

📋 Manual Details

Manual Type:

Factory Repair Manual

Language:

English

Format:

Digital (likely PDF, verifiable upon acquisition)

Estimated Page Count:

Approximately 1500-2000 pages (typical for a comprehensive factory manual of this era)

📖 Manual Coverage

Engine Service:

Complete diagnostic, repair, and overhaul procedures for all engine variants

Transmission Service:

Detailed procedures for automatic transmission diagnosis, repair, and maintenance

Brake System:

Diagnosis and repair of ABS, hydraulic components, parking brake, and rotor/pad replacement

Suspension Steering:

Front and rear suspension components, steering gear, power steering system, alignment specifications

Electrical System:

Wiring diagrams, component testing, starter, alternator, battery, lighting, power windows, locks, and accessories

HVAC:

Air conditioning system diagnosis, refrigerant handling, heater core, blower motor, climate control

Body And Trim:

Exterior panel repair, interior trim removal and installation, glass replacement

Diagnostic Troubleshooting:

Systematic fault finding and diagnostic procedures for all major vehicle systems

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, evaporative emissions system

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors

Cooling System:

Radiator, fan, thermostat, water pump, coolant hoses, heater core

Routine Maintenance:

Oil change, filter replacement, fluid checks, tire rotation, tune-up procedures

Component Replacement:

Step-by-step instructions for replacing major components (e.g., water pump, alternator, starter, fuel pump)

Engine Rebuild:

Detailed specifications and procedures for engine disassembly, inspection, and reassembly

Transmission Overhaul:

Complete overhaul procedures for the automatic transmission, including clutch pack replacement and valve body service

Brake System Repair:

Front and rear brake pad and rotor replacement, caliper service, brake line bleeding

Electrical Component Testing:

Testing procedures for sensors, actuators, ignition system components, and body control modules

Diagnostics Trouble Codes:

Interpretation and troubleshooting of all diagnostic trouble codes (DTCs) relevant to the 2002 model year

Wheel Bearing Replacement:

Procedures for front and rear wheel bearing replacement

Diagnostic Capabilities:

Comprehensive diagnostic flowcharts, trouble codes (DTCs), and symptom-based troubleshooting

Repair Complexity:

Covers basic DIY maintenance to complex mechanical and electrical repairs requiring specialized tools

Specification Accuracy:

Includes precise torque specifications, clearances, fluid capacities, and electrical resistance values

Wiring Diagrams:

Includes detailed, system-specific wiring diagrams for accurate electrical troubleshooting

📊 Manual Specifications

Digital Format:

PDF (typically, high-resolution scans of original factory documentation)

Scan Quality:

High-resolution scans ensuring readability of text, diagrams, and illustrations

Digital Format Advantage:

Searchable text and easy navigation via bookmarks, no physical binding concerns

Original Document Type:

Factory-produced technical documentation on durable paper stock

⚙️ Engine Specifications

Engine Code:

EGA (3.3L V6)

Displacement:

3.3 Liters (204 cubic inches)

Configuration:

SOHC V6

Horsepower:

180 hp @ 5000 rpm (approx.)

Torque:

200 lb-ft @ 3200 rpm (approx.)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Engine Variant 2:

Optional: 3.8L V6 (EPH code), 190-200 hp, 230-235 lb-ft torque (check specific vehicle VIN)

Spark Plugs:

Champion RC12LYC or equivalent (gap 0.045")

Engine Oil Type:

SAE 5W-30 API Certified

Engine Oil Capacity:

4.5 US quarts (4.3 Liters) with filter

🔧 Transmission

Transmission Type:

4-speed Automatic

Transmission Model:

Chrysler 41TE / 42LE

Overdrive:

Yes (4th gear)

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approximately 4.0 US quarts (3.8 Liters) for fluid change with filter replacement

📐 Dimensions

Wheelbase:

119.3 inches (3030 mm)

Length:

195.8 inches (4973 mm)

Width:

76.7 inches (1948 mm)

Height:

68.4 inches (1737 mm)

Curb Weight:

Approx. 4100-4300 lbs (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Approx. 5700-5900 lbs

Cargo Volume Behind 3Rd Row:

Approx. 15 cubic feet

Cargo Volume Behind 2Nd Row:

Approx. 57 cubic feet

Cargo Volume Max:

Approx. 145 cubic feet

Towing Capacity:

Up to 3800 lbs (with optional towing package and proper trailer weight distribution)

🛡️ Safety Features

NHTSA Frontal Impact Driver:

★★★★ (4 Stars)

NHTSA Frontal Impact Passenger:

★★★★ (4 Stars)

IIHS Frontal Offset:

Good

ABS:

Standard Anti-lock Braking System

Traction Control:

Optional Traction Control System (TCS)

Airbags:

Front driver and passenger airbags; Optional front-side airbags

Seat Belts:

3-point seat belts for all occupants, driver's seatbelt reminder

💡 Technology Features

Audio System:

Factory AM/FM/CD or Cassette/CD player options; premium Infinity sound system available

Rear Entertainment:

Optional rear-seat entertainment system with video screen and headphone jacks

Cruise Control:

Standard cruise control

Power Accessories:

Power windows, power door locks, power mirrors were common features

Remote Keyless Entry:

Available remote keyless entry system

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (under normal driving conditions)

Transmission Fluid Change:

Every 30,000 miles or 24 months (recommended service, especially for heavy use)

Coolant Change:

Initial change at 100,000 miles, then every 50,000 miles (or every 5 years)

Spark Plug Replacement:

Every 100,000 miles (long-life platinum or iridium plugs)

Power Steering Fluid:

ATF+4 (Mopar)

Coolant Type:

Chrysler OAT (Organic Acid Technology) HOAT (Hybrid OAT) Pink or equivalent long-life antifreeze

Brake Fluid Type:

DOT 3

Transmission Solenoids:

Intermittent shifting issues or no-shift condition can be related to failing solenoids in the 41TE/42LE transmission

Water Pump Leaks:

Common for the water pump to develop leaks over time, often requiring replacement

Power Window Motors:

Failure of power window motors and regulators is a relatively common issue

Rear Wiper Motor:

The rear wiper motor assembly can corrode and fail

Cv Axle Boots:

Torn CV axle boots can lead to joint failure if not addressed promptly

📚 Vehicle History

Chrysler Minivan Legacy:

Chrysler is credited with inventing the modern minivan segment with the 1984 Dodge Caravan/Plymouth Voyager

Ns Generation:

The 2002 model year falls within the second generation (NS platform, 1996-2000) and the first year of the third generation (RS platform, 2001-2007) for the Chrysler Voyager. This manual likely covers the RS generation transition or specifically the 2002 RS model.

Manufacturing Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

Model Year Context:

2002 marked a significant redesign and introduction of the RS platform, featuring updated styling, chassis, and interior.

🏆 Awards & Recognition

Car And Driver 10Best:

The original Chrysler minivan was a recurring recipient of Car and Driver's 10Best awards; the 2002 model continued to be a strong contender in its segment.

Consumer Reports:

Often rated as average to above average for its class in reliability and owner satisfaction, though specific year ratings can vary.