Chrysler Town & Country 2002 Service Repair Workshop Manual

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The Chrysler Town & Country, produced for the 2002 model year, represents a significant offering in the minivan segment. This RG generation vehicle, built on the Chrysler NS platform, was...

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Description

The Chrysler Town & Country, produced for the 2002 model year, represents a significant offering in the minivan segment. This RG generation vehicle, built on the Chrysler NS platform, was engineered with a focus on family-oriented functionality, boasting a spacious interior, versatile seating arrangements, and a comfortable ride. Powered by a reliable 3.3L V6 engine delivering 180 horsepower and 205 lb-ft of torque, it provided ample performance for transporting passengers and cargo. Key features that distinguished the Town & Country included its emphasis on interior versatility and a comfortable, family-friendly experience, positioning it as a strong competitor against other minivans of its time. This comprehensive workshop and service repair manual provides extensive coverage for the 2002 Chrysler Town & Country, detailing complete service and repair procedures. It covers all major systems, including engine mechanicals and management, the 41TE/42LE automatic transaxle, brakes, suspension, steering, electrical systems, HVAC, bodywork, and safety restraints. The manual offers detailed guidance on preventative maintenance, diagnostics, troubleshooting, component replacement, and includes essential technical specifications and torque values. With over 1000 pages of information, this English-language manual is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing the vehicle.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Town & Country

Year:

Generation

Generation Code:

Codes

Platform:

Chrysler NS

👋 Introduction

Market Position

Segment:

Minivan

Key Selling Points:

Family-oriented, spacious interior, flexible seating configurations, comfortable ride

Competitive Analysis

Main Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Vans

Key Features

Interior Versatility:

Designed with family transport in mind, offering ample passenger and cargo space. Later models would introduce the popular Stow 'n Go seating.

Powertrain Options:

Reliable V6 engines providing adequate power for hauling families and cargo.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Secondary Coverage:

Maintenance, Diagnostics, Troubleshooting, Overhaul

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Workshop Manual / Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul, diagnosis, and repair of all engine components (cylinder head, block, pistons, crankshaft, camshafts, timing systems)

Engine Management:

Fuel injection system (MPI), ignition system, emissions control systems, engine sensors, diagnostic trouble codes (DTCs), Powertrain Control Module (PCM) operations

Transmission Automatic:

41TE/42LE Automatic Transaxle: Repair, overhaul, hydraulic control systems, torque converter, electronic controls, diagnostic procedures

Brakes:

Front and rear disc brakes, anti-lock braking system (ABS) components, hydraulic lines, master cylinder, calipers, pads, rotors, bleeding procedures

Suspension:

Front independent suspension (MacPherson struts), rear beam axle with trailing arms, shock absorbers, springs, bushings, alignment specifications

Steering:

Power steering system (pump, rack and pinion, hoses), steering column, tie rods, alignment

Electrical System:

12V battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, power distribution

HVAC:

Air conditioning system (compressor, refrigerant, condenser, evaporator), heating system, blower motor, climate control unit, diagnosis and repair

Body Interior:

Body panels, doors, windows, seats, interior trim, liftgate, Stow 'n Go system (if applicable to certain configurations), body repair procedures

Body Exterior:

Bumpers, fenders, hood, grille, mirrors, exterior trim, paint and corrosion protection

Safety Restraints:

Airbag system (SRS), seat belts, pretensioners, SRS module diagnostics

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections

Troubleshooting:

Diagnostic procedures for all major systems, symptom-based troubleshooting guides, interpretation of diagnostic trouble codes (DTCs)

Repair Rebuild:

Complete repair and overhaul procedures for engine, transmission, suspension, steering, brakes, and other major mechanical components

Electrical Diagnostics:

Step-by-step diagnostic routines for electrical faults, using wiring diagrams and multimeter testing

Component Replacement:

Detailed instructions for replacing specific parts such as water pump, alternator, starter, fuel pump, brake pads, etc.

Torque Specifications:

All critical torque values for engine, chassis, and body fasteners

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostic strategies.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval

Print Quality:

High-resolution scans, optimized for printing

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

3.3L (3301cc) V6 OHV 12-Valve

Bore X Stroke:

3.88 x 3.08 inches (98.6 x 78.2 mm)

Compression Ratio:

9.0:1

Horsepower:

180 hp @ 5000 rpm

Torque:

205 lb-ft @ 3000 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Engine Oil

Oil Type:

SAE 5W-30 (API Certified)

Oil Capacity:

4.5 US quarts (4.3 Liters) with filter change

Cooling System

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (Blue)

Coolant Capacity:

12.0 US quarts (11.4 Liters)

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Transmission Model:

41TE / 42LE

Features

Overdrive:

Electronic Control:

Yes (Electronic Pressure Control)

Fluid Specifications

Fluid Type:

Chrysler ATF+4 (Automatic Transmission Fluid)

Fluid Capacity

Capacity:

7.5 US quarts (7.1 Liters) dry fill

📐 Dimensions

Exterior

Length:

195.7 inches (4971 mm)

Width:

77.7 inches (1974 mm)

Height:

68.7 inches (1745 mm)

Wheelbase:

120.0 inches (3048 mm)

Front Track:

65.0 inches (1651 mm)

Rear Track:

65.0 inches (1651 mm)

Weights

Curb Weight:

4,338 - 4,612 lbs (1968 - 2092 kg) depending on configuration

Gross Vehicle Weight Rating Gvwr:

5,750 - 6,000 lbs (2608 - 2722 kg)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 30.1 cu ft

Cargo Volume Behind 2Nd Row:

Approx. 81.1 cu ft

Cargo Volume Max:

Approx. 143.7 cu ft

Towing

Towing Capacity:

3,500 lbs (1588 kg) with optional towing package

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

★★★★☆ (4 Stars)

NHTSA Passenger Front Impact:

★★★★☆ (4 Stars)

IIHS Moderate Overlap Frontal Offset:

Active Features

Standard (Anti-lock Braking System)

Traction Control:

Optional (Traction Control System - TCS)

Passive Features

Airbags:

Standard front airbags for driver and front passenger; optional side airbags.

Seat Belts:

Three-point seat belts for all seating positions; front seat pretensioners.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player; optional premium audio systems with more speakers, cassette player, or rear entertainment screens.

Navigation:

Optional factory navigation system (rare for 2002).

Driver Assistance

Cruise Control:

Standard

Parking Sensors:

Optional rear parking assist.

Connectivity

Auxiliary Input:

Not standard; aftermarket solutions available.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type used.

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed.

Spark Plugs:

Recommended replacement every 100,000 miles (160,000 km) with high-quality iridium or platinum plugs.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-97,000 km), depending on driving habits and fluid condition. Always use ATF+4.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years.

Fluid Specifications

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent DEXRON-III/MERCON automatic transmission fluid.

Known Issues

Transmission Problems:

Early 41TE/42LE transmissions were known for intermittent shifting issues, solenoid failures, and wear in the clutch packs. Regular fluid changes with the correct ATF+4 are critical.

Engine Performance:

Some models experienced head gasket issues, though less common on the 3.3L than other Chrysler engines of the era. Carbon buildup can affect performance.

Electrical Faults:

Wiring harness issues, especially in door hinges, and faulty power window motors are not uncommon.

HVAC System:

Blend door actuator failures can cause HVAC temperature control problems. AC compressor clutch failures can also occur.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in the mid-1980s, and the Town & Country has always represented its premium offering in this category.

Model Evolution

Rg Generation Context:

The 2002 model year marks the first year of the fourth generation (RG) of the Chrysler Town & Country, a significant redesign from the previous generation, offering improved styling, safety, and features.

Production

Assembly Locations:

Windsor, Ontario, Canada (Windsor Assembly Plant)

Production Years

Model Years Covered By Rg:

2001-2007

🏆 Awards & Recognition

Recognitions

Consumer Satisfaction:

While not consistently topping reliability charts for its era, the Town & Country was praised for its practicality and family features, often ranking well in owner satisfaction surveys for its segment.

Ratings

Kbb Value Ratings:

As a 2002 model, its value is primarily in the used market, where condition and mileage are key factors. The manual's coverage is crucial for maintaining its value.