🏷️ Basic Information

Make:

Chrysler

Model:

Voyager

Year:

2002

Chassis Code:

GS (North America)

👋 Introduction

Vehicle Segment:

Minivan

Target Audience:

Families, individuals requiring versatile passenger and cargo space.

Key Competitors:

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

Versatility:

Known for its spacious interior, flexible seating arrangements, and practical utility.

Value Proposition:

Often positioned as a more budget-friendly option within its segment.

📋 Manual Details

Manual Type:

Full Service & Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul and repair procedures for all gasoline engines, including cylinder head, block, pistons, crankshaft, timing system, lubrication, and cooling.

Engine Performance:

Diagnosis and repair of engine performance issues, including fuel delivery, ignition system, emissions control, and engine management systems.

Transmission Automatic:

Complete repair and overhaul instructions for the automatic transmission (e.g., 41TE/AE), including valve body, torque converter, planetary gears, and hydraulic systems.

Transmission Manual:

Repair and maintenance for manual transmission variants if applicable for the 2002 model year.

Drivetrain:

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

Suspension:

Front and rear suspension components, including struts, shock absorbers, control arms, ball joints, sway bars, and wheel bearings. Alignment specifications included.

Steering:

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

Brakes:

Front and rear disc brake systems, including calipers, rotors, pads, hydraulic lines, master cylinder, and ABS (Anti-lock Braking System) diagnosis and repair.

Electrical System:

Comprehensive coverage of the vehicle's electrical system, including battery, charging system (alternator), starter, ignition system, lighting, and power distribution.

Body Electrical:

Diagnosis and repair of body control modules (BCM), power windows, door locks, mirrors, interior and exterior lighting, and accessory circuits.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, including refrigerant handling, compressor, condenser, evaporator, and blower motor.

Interior Components:

Removal and installation procedures for interior trim, seats, dashboard, and console components.

Exterior Body:

Body panel removal and installation, including doors, hood, tailgate, fenders, bumpers, and associated hardware. Rust repair and corrosion prevention advice.

Routine Maintenance:

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

Troubleshooting:

Systematic diagnostic procedures for common and complex problems, including symptom-based troubleshooting guides and diagnostic trouble codes (DTCs).

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, inspection, machining, and reassembly.

Transmission Rebuild:

Detailed procedures for the overhaul of the automatic transmission, including torque specifications and assembly sequences.

Brake Repair:

Replacement of brake pads, rotors, calipers, and bleeding of the brake system.

Electrical Diagnosis:

Wiring diagrams, component testing, and troubleshooting of electrical faults.

HVAC Service:

Recharging the A/C system, leak detection, and component replacement.

Suspension And Steering Repair:

Replacement of ball joints, tie rod ends, struts, and shocks.

Body And Interior Repair:

Procedures for removing and installing body panels, interior trim, and seating.

Depth Level:

Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, with detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Yes, the PDF is likely optimized for keyword searching, allowing quick access to specific topics.

Print Quality:

Typically high-resolution, suitable for printing individual pages or sections.

Binding:

Not Applicable (PDF Download)

Paper:

Not Applicable (PDF Download)

Completeness:

Full Service and Repair Manual, intended to cover all aspects of vehicle maintenance and repair.

⚙️ Engine Specifications

Engine Code Variant 1:

3.3L V6 (EGA)

Displacement Variant 1:

3301 cc (201.5 cubic inches)

Configuration Variant 1:

Overhead Valve (OHV), 2 valves per cylinder

Horsepower Variant 1:

Approx. 180 hp @ 5000 rpm

Torque Variant 1:

Approx. 205 lb-ft @ 3200 rpm

Engine Code Variant 2:

3.8L V6 (L32)

Displacement Variant 2:

3778 cc (230.5 cubic inches)

Configuration Variant 2:

Overhead Valve (OHV), 2 valves per cylinder

Horsepower Variant 2:

Approx. 200 hp @ 4400 rpm

Torque Variant 2:

Approx. 240 lb-ft @ 3000 rpm

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Unleaded gasoline, 87 octane recommended

Emission System:

On-Board Diagnostics (OBD-II), catalytic converter, EGR (Exhaust Gas Recirculation).

🔧 Transmission

Transmission Type:

4-speed Automatic Transaxle (e.g., 41TE/AE)

Optional Transmission:

Not typically offered for this model year, predominantly automatic.

Transmission Fluid:

ATF+4 (Chrysler Material Standard MS-9602) is a common specification, consult manual for exact type and capacity.

Gear Ratios:

Specific gear ratios for each gear and final drive would be detailed in the manual.

📐 Dimensions

Length:

Approx. 193.7 inches

Width:

Approx. 76.7 inches

Height:

Approx. 67.7 inches

Wheelbase:

Approx. 112.1 inches

Passenger Volume:

Refer to specific trim level specifications, typically spacious for its class.

Cargo Volume:

Significant cargo capacity, especially with rear seats removed/folded. Exact figures vary by configuration.

Curb Weight:

Approx. 3800 - 4200 lbs depending on engine and trim.

Gross Vehicle Weight Rating:

Refer to vehicle's VIN plate for exact GVWR.

🛡️ Safety Features

NHTSA Frontal Impact:

Varies by specific test year and configuration, but generally aimed to meet or exceed contemporary safety standards. Detailed ratings would require specific testing documentation.

IIHS Crash Test:

Similarly, specific IIHS ratings would need to be sourced from their archives.

ABS:

Standard Anti-lock Braking System (ABS) on most or all trims.

Traction Control:

Optional traction control system available on some models.

Airbags:

Driver and front passenger airbags. Side airbags may have been optional depending on trim.

Seatbelts:

Three-point seatbelts for all outboard seating positions. Child seat anchors (LATCH) system.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with CD player or cassette tape. Premium audio options may exist depending on trim.

Navigation System:

Factory navigation systems were not common or widely available for this model year. Aftermarket options were more prevalent.

Cruise Control:

Standard cruise control functionality.

Rear Parking Sensors:

Optional rear parking assist system may have been available on higher trims.

Auxiliary Input:

Factory auxiliary inputs for external audio devices were not standard. Aftermarket solutions would be required.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions. Consult manual for specific recommendation.

Transmission Fluid Change:

Recommended every 30,000-60,000 miles or as per manual, especially for heavy-duty use.

Coolant Flush:

Typically every 30,000-100,000 miles or 2-5 years, depending on coolant type.

Spark Plug Replacement:

For the V6 engines, often at 100,000 miles with platinum or iridium tipped plugs.

Engine Oil:

SAE 5W-30 is a common recommendation for the V6 engines, consult manual for exact viscosity and API service classification (e.g., API SN or newer).

Coolant:

Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), typically a 50/50 mix with distilled water. Check manual for specific Mopar part number or equivalent.

Brake Fluid:

DOT 3 brake fluid.

Power Steering Fluid:

Chrysler Power Steering Fluid or a specified ATF type. Refer to manual for exact specification.

Transmission Hard Shifts:

Some models may experience hard shifting or transmission slippage, often related to valve body issues or low fluid levels/condition. The manual will guide diagnosis.

Idler Pulley Noise:

The serpentine belt idler pulley can sometimes become noisy and require replacement.

Headlight Switch Failure:

Intermittent headlight operation or failure of the headlight switch is a known issue on some models.

Power Sliding Door Actuator:

For models equipped with power sliding doors, the actuator mechanism can wear out and require service.

📚 Vehicle History

Chrysler Minivan Legacy:

Chrysler is widely credited with pioneering the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in the mid-1980s. The Voyager nameplate has a long-standing association with family utility vehicles.

Generation:

This 2002 model year falls within the second generation of the Chrysler minivan platform (GS body style), which saw significant updates and refinements over its predecessors.

Manufacturing Location:

Primarily manufactured in North America, with significant production at the Windsor Assembly Plant in Windsor, Ontario, Canada.

Production Years For Gs:

1996-2000 (initial phase), with updates and facelifts continuing through to the 2007 model year for certain markets/variations, though the core GS platform was updated and eventually replaced.

🏆 Awards & Recognition

Car And Driver 10Best:

While Chrysler minivans have historically been well-regarded, specific awards for the 2002 Voyager would need to be verified through automotive publication archives.

Consumer Reports Reliability:

Reliability ratings can vary by model year and specific components. The manual will help in identifying potential issues and their solutions.

Epa Fuel Economy:

EPA estimates for the 2002 Voyager typically ranged from 17 MPG city / 23 MPG highway for the 3.3L V6, but exact figures depend on specific configurations and driving conditions. The manual might provide relevant specifications.