Chrysler Voyager 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2002 Codes Platform Code: NS/GS (North America/Europe) Engine Code Common: EDZ (3.3L V6 OHV) Engine Code Optional: EGW (3.8L V6 OHV)...

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Type: Car

Vendor:

Sku: 24425

Tags: 2002 Car Chrysler Marine Misc Outboard Engines Voyager

Product variants

Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Year:

Codes

Platform Code:

NS/GS (North America/Europe)

Engine Code Common:

EDZ (3.3L V6 OHV)

Engine Code Optional:

EGW (3.8L V6 OHV)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, individuals seeking versatile passenger and cargo transport

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager

Key Features

Versatility:

Spacious interior, flexible seating configurations, ample cargo space

Powertrain Options:

Reliable V6 engines offering a balance of power and efficiency

Comfort And Convenience:

Focus on passenger comfort, available features like power sliding doors, rear entertainment systems (on higher trims)

Value Proposition

Benefit To Owner:

Empowers owners to perform maintenance and repairs, saving on labor costs and ensuring proper vehicle upkeep.

📋 Manual Details

Coverage Areas

Countries Covered:

North America, Europe (and other markets where the Voyager was sold)

Trim Levels Covered:

All trim levels (e.g., SE, LX, LXi, ES)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (3.3L, 3.8L), Transmission (41TE/AE Automatic), Drivetrain

Chassis:

Suspension, Steering, Brakes, Wheels, Tires

Electrical:

Body Electrical, Powertrain Control Module (PCM), Lighting, HVAC Controls, Instruments and Gauges, Audio System, Power Accessories

Body:

Body Panels, Doors, Glass, Interior Trim, Seats, Roof Systems (including Stow 'n Go where applicable, though less common for 2002), Exterior Trim

HVAC:

Air Conditioning, Heating, Ventilation, Climate Control Systems

Safety Systems:

Airbags, Seat Belts, ABS (Anti-lock Braking System), Traction Control

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tune-ups, belt and hose inspections

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their meanings

Repair:

Engine component repair/replacement, transmission overhaul, brake system repair, electrical component repair, bodywork repair

Disassembly Assembly:

Detailed step-by-step instructions for removing, disassembling, and reassembling major vehicle components and systems

Special Tools:

Identification and usage of specialized tools required for specific repair procedures

Technical Depth

Depth:

Comprehensive, from basic adjustments to complete engine and transmission rebuilds

Diagnostics Level:

Advanced diagnostic procedures utilizing scan tools and multimeter testing

Wiring Diagrams:

Detailed electrical wiring schematics for all vehicle systems

📊 Manual Specifications

File Format

Type:

Searchability:

Searchable text (typically)

Print Quality

Quality:

High-resolution, suitable for printing

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Displacement:

3.3 Liters (201 cubic inches)

Configuration:

V6, Overhead Valve (OHV), 2 valves per cylinder

Bore X Stroke:

3.44 in x 3.75 in (87.3 mm x 95.2 mm)

Compression Ratio:

8.9:1

Horsepower Net Std:

158 hp @ 4600 RPM

Torque Net Std:

190 lb-ft @ 3200 RPM

Optional Engine

Displacement:

3.8 Liters (230 cubic inches)

Configuration:

V6, Overhead Valve (OHV), 2 valves per cylinder

Horsepower Net Std:

180 hp @ 4500 RPM

Torque Net Std:

230 lb-ft @ 3200 RPM

Fuel System

Type:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline, 87 Octane (Minimum)

Ignition System

Type:

Distributorless Ignition System (DIS)

Cooling System

Type:

Pressurized, liquid-cooled

🔧 Transmission

Standard

Type:

4-Speed Automatic Transaxle (41TE/AE)

Gear Ratios 3.3L:

Refer to manual for specific ratios (e.g., 1st: 2.80, 2nd: 1.51, 3rd: 1.00, Rev: 2.21)

Optional

Type:

N/A (4-Speed Automatic was standard across all engines for this model year)

Features

Control:

Electronic controls with adaptive shift logic

Fluid Specifications

Type:

Chrysler ATF+4 (MS-9602)

Fluid Capacity

Capacity Approx:

Dry Fill: 8.0 Quarts (7.6 Liters), Refill: 4.5 Quarts (4.3 Liters)

📐 Dimensions

Exterior

Wheelbase:

119.3 inches (3030 mm)

Length:

196.3 inches (4986 mm)

Width:

76.7 inches (1948 mm)

Height:

68.7 inches (1745 mm)

Interior

Seating Capacity:

7-8 Passengers

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 15-20 cu. ft. (depending on configuration)

Cargo Volume Max:

Approx. 140-150 cu. ft. (with seats removed/folded)

Weights

Curb Weight Approx:

4100 - 4400 lbs (1860 - 2000 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5700 - 5800 lbs (2585 - 2630 kg)

Towing Capacity Max:

3500 lbs (1588 kg) with optional towing package

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

★★★★ (4-Star)

NHTSA Front Impact Passenger:

★★★★ (4-Star)

NHTSA Side Impact Front Seat:

★★★★ (4-Star)

NHTSA Side Impact Rear Seat:

★★★★★ (5-Star)

IIHS Rollover Rating:

Acceptable

Active Features

Standard (4-wheel disc brakes on most trims, front disc/rear drum on some base models)

Traction Control:

Optional (often tied to ABS)

Passive Features

Airbags:

Driver and front passenger airbags; optional side-impact airbags

Seat Belts:

3-point seat belts with pretensioners for front seats, 3-point belts for second and third rows

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system in second-row seating positions

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player or cassette player. Optional premium Infinity sound system.

Rear Entertainment:

Optional rear-seat video system with flip-down screen and wireless headphones available on higher trims.

Driver Assistance

Cruise Control:

Standard on most models

Parking Sensors:

Optional rear parking assist system

Connectivity

Remote Keyless Entry:

Optional

Power Sliding Doors:

Optional on most trims, standard on some higher trims.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations)

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed

Spark Plugs Replacement:

30,000-60,000 miles (48,000-96,000 km) depending on plug type (e.g., platinum)

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km), or more frequently if towing or under severe use

Fluid Specifications

Engine Oil:

SAE 5W-30 (API Service SG or higher)

Coolant:

Chrysler Long Life 50/50 Antifreeze/Coolant (or equivalent HOAT - Hybrid Organic Acid Technology)

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF+4 (MS-9602) or Mopar Power Steering Fluid

Known Issues

Transmission Hard Shifting:

Common issue with the 41TE transmission, often related to solenoid pack or valve body wear. Manual details diagnostic and repair procedures.

Power Door Actuator Failure:

Sliding or liftgate power door actuators can fail. Manual covers diagnosis and replacement.

Ignition Coil Failure:

Individual ignition coils or the coil pack can fail, leading to misfires. Manual provides testing procedures.

Blend Door Actuator HVAC:

HVAC blend door actuators can fail, causing temperature control issues. Manual details access and replacement.

Wheel Bearing Wear:

Front wheel bearings can wear prematurely. Manual covers inspection and replacement procedures.

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles)

Minivan Pioneering:

Chrysler is widely credited with inventing the modern minivan segment with the Dodge Caravan/Plymouth Voyager in 1983.

Model Evolution

Generation:

Second Generation (NS) - Introduced for the 1996 model year. The 2001 redesign marked the beginning of the Third Generation (RS).

2002 Updates:

Minor revisions, potential package adjustments. The 2002 model year falls within the RS generation, which featured a more aerodynamic design, improved chassis, and updated powertrains.

Global Variants:

The Chrysler Voyager was the European counterpart to the Dodge Grand Caravan, offering slightly different styling and features for international markets.

Production

Manufacturing Locations:

Windsor Assembly Plant, Windsor, Ontario, Canada

Production Years Relevant:

1996-2007 (NS/RS Generations)

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

The Chrysler Minivan platform (including Voyager/Grand Caravan) was frequently recognized by Car and Driver, though specific 2002 awards may vary.

Consumer Reports:

Consumer Reports ratings for reliability and satisfaction varied; the manual is crucial for maintaining a vehicle to achieve optimal performance and longevity.