Chrysler Grand Voyager 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Grand Voyager Year: 2002 Codes Platform: RS (Voyager/Caravan/Town & Country) 👋 Introduction Market Position Segment: Full-size minivan, family vehicle Competitive Analysis Key Competitors:...

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标签: 2002 Car Cars Chrysler Grand Voyager

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Grand Voyager

Year:

Codes

Platform:

RS (Voyager/Caravan/Town & Country)

👋 Introduction

Market Position

Segment:

Full-size minivan, family vehicle

Competitive Analysis

Key Competitors:

Dodge Grand Caravan, Plymouth Grand Voyager (pre-2001), Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna.

Key Features

Vehicle Type:

Minivan

Passenger Capacity:

Typically 7-8 passengers with available second and third-row seating configurations.

Versatility:

Known for its spacious interior, flexible seating arrangements (Stow 'n Go not yet introduced), and family-oriented features.

📋 Manual Details

Coverage Areas

Geographic Coverage:

North America (Chrysler Grand Voyager)

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed procedures for engine disassembly, assembly, diagnosis, and repair, including cylinder heads, pistons, crankshafts, camshafts, and timing systems.

Engine Electrical:

Covers ignition system, fuel injection system, starting system, charging system, engine control module (ECM) diagnostics, and wiring diagrams.

Transmission Automatic:

Comprehensive repair and diagnostic procedures for the automatic transmission, including valve body, torque converter, clutches, bands, and electronic controls.

Drivetrain:

Front-wheel drive system, including CV joints, driveshafts, differential, and related components.

Suspension:

Front and rear suspension systems, including shock absorbers, struts, control arms, bushings, ball joints, and wheel bearings.

Steering:

Power steering system, including pump, steering gear, tie rods, and power steering fluid specifications.

Brakes:

Front and rear brake systems, including disc brakes, calipers, brake pads, rotors, master cylinder, brake fluid, ABS system diagnostics, and parking brake.

Electrical Chassis:

Lighting systems (headlights, taillights, interior), horn, wipers, washers, power windows, power locks, mirrors, and related switches.

HVAC:

Heating, ventilation, and air conditioning system, including refrigerant charging, compressor, evaporator, condenser, blower motor, and climate controls.

Body Interior:

Interior trim removal and installation, seats, dashboard, door panels, headliner, and body panel components.

Body Exterior:

Exterior body panels, doors, hood, liftgate, bumpers, glass, and seals.

Diagnostics Troubleshooting:

Extensive diagnostic procedures, common fault codes (DTCs), symptom-based troubleshooting guides, and diagnostic flowcharts for all major systems.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, and inspections.

Repair:

Step-by-step repair instructions for component removal, disassembly, assembly, and installation for all major vehicle systems.

Adjustment:

Procedures for adjustments to various components, such as brakes, clutch, throttle linkage, and parking brake.

Installation:

Detailed instructions for the installation of new or replacement parts and components.

Removal:

Step-by-step instructions for the safe and proper removal of vehicle components.

Technical Depth

Depth:

Comprehensive, from basic maintenance to advanced diagnostics and complete rebuilds, suitable for professional technicians and experienced DIYers.

Diagnostic Tools:

Reference to special service tools and equipment required for various repair and diagnostic procedures.

Schematics:

Includes detailed wiring diagrams, vacuum diagrams, and exploded view diagrams to illustrate component relationships and service procedures.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printable:

Yes, all pages are printable.

Binding Type

Binding:

Digital Download (Printable PDF)

Paper Type

Paper Type:

N/A (Digital)

Software Requirement

Requirement:

Adobe Reader

Compatibility

Os Compatibility:

Windows, Mac, Linux

⚙️ Engine Specifications

Primary Engine

Engine Code:

EGA (3.3L V6)

Displacement:

3.3 Liters (3301 cc)

Configuration:

Overhead Valve (OHV), V6

Horsepower:

Approximately 158 hp @ 4600 rpm (for 3.3L EGA)

Torque:

Approximately 190 lb-ft @ 3200 rpm (for 3.3L EGA)

Optional Engine

Engine Code:

L30 (3.8L V6)

Displacement:

3.8 Liters (3778 cc)

Horsepower:

Approximately 180 hp @ 4600 rpm (for 3.8L L30)

Torque:

Approximately 240 lb-ft @ 3200 rpm (for 3.8L L30)

Fuel System

Fuel Delivery:

Multi-port fuel injection (MPI)

Fuel Type:

Unleaded gasoline

🔧 Transmission

Standard

Transmission Type:

4-speed automatic

Transmission Model:

Optional

Optional Transmission:

N/A (Standard for this generation)

Features

Gear Ratios:

Detailed gear ratios are available within the manual for specific transmission model 41TE.

Fluid Type:

ATF+4 (Chrysler Automatic Transmission Fluid, Type 9602)

Fluid Capacity:

Approximately 10.5 quarts (9.9 liters) for a dry fill, significantly less for a drain and refill.

📐 Dimensions

Exterior

Length:

Approximately 196.4 inches (4989 mm)

Width:

Approximately 78.5 inches (1994 mm) (excluding mirrors)

Height:

Approximately 67.8 inches (1722 mm) (unloaded)

Wheelbase:

Approximately 119.3 inches (3030 mm)

Weights

Curb Weight:

Approximately 4,000 - 4,300 lbs (1814 - 1950 kg), varies by engine and trim.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

The 2002 Grand Voyager generally received good ratings in frontal crash tests from NHTSA, with some models achieving 4 or 5 stars.

IIHS Ratings:

IIHS ratings were typically good for frontal impacts for this generation of Voyager.

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

Optional traction control system available on some models.

Passive Features

Airbags:

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

Seat Belts:

Three-point seat belts for all outboard seating positions, integrated shoulder belts for center seats.

💡 Technology Features

Infotainment

Audio System:

Optional premium audio systems with CD player, cassette player, and available rear seat entertainment systems.

Driver Assistance

Cruise Control:

Standard cruise control.

Keyless Entry:

Optional keyless entry system.

Connectivity

Usb Ports:

Not available on this model. Connectivity was limited to audio inputs.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 miles (12,000 km) or 6 months, under normal driving conditions, but refer to manual for severe conditions.

Tire Rotation:

Recommended every 7,500 miles (12,000 km).

Transmission Fluid Change:

Recommended every 60,000 - 100,000 miles (96,000 - 160,000 km), or sooner under severe usage. Manual provides specific guidance.

Fluid Specifications

Engine Oil Spec:

API Certified SAE 5W-30 or 5W-40, meeting Chrysler MS-6395 specification.

Coolant Spec:

Chrysler Formula Antifreeze/Coolant (AFR), a blend of ethylene glycol and deionized water.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Known Issues

Transmission Slippage:

The 41TE transmission can be prone to issues like slippage, harsh shifting, and premature failure if not properly maintained or if the valve body develops problems.

Power Sliding Door:

Some models may experience issues with the power sliding door motor or mechanism.

Window Regulators:

Power window regulators can sometimes fail over time.

Front Suspension Wear:

Wear of suspension components such as ball joints and tie rod ends is not uncommon due to vehicle weight and usage.

📚 Vehicle History

Brand Heritage

Chrysler Legacy:

Chrysler is renowned for pioneering the minivan segment with the original Dodge Caravan and Plymouth Voyager in the mid-1980s.

Model Evolution

Generation:

This 2002 model represents the second generation of the 'NS' platform Voyager, which began in 1996, with significant updates in 1999 and 2001.

Production

Manufacturing Plant:

Primarily manufactured in Windsor, Ontario, Canada.

Production Years:

The second generation (NS) ran from 1996 to 2000, with the updated NS/RS platform (facelifted) starting in model year 2001. The 2002 model falls within this updated phase.

🏆 Awards & Recognition

Recognitions

Automotive Journalism:

While specific awards for the 2002 model year are not prominently recalled, the Grand Voyager (and its Dodge/Plymouth siblings) consistently received praise for family practicality and space in automotive reviews of the era.