Dodge Intrepid 2002 Service Manual Set (P/N 81-270-02027)

The diagnostic books organize tests by fault code or symptom. When a test identifies a failed component, the service manual provides the related removal, installation, or overhaul procedure.

Searchable Service Text and Bookmarked Chapters

Text search and diagram detail: All five manuals have chapter bookmarks and searchable service or diagnostic text. Many Group 8W wiring sheets and some labels in the diagnostic schematics are outside the text search. Zoom in to read small pin numbers and wire codes. The separate cover and navigation PDFs use clickable links.

The ZIP contains 2,990 pages across seven printable PDFs, including a separate two-page cover and foreword and a one-page navigation menu. The total also includes the blank pages, notes pages, and comment form within the manuals.

Engine, Transaxle, Brake, and Electrical Service

These selected topics show the range of repair and diagnostic coverage. Other examples include headlamp aiming and tire-pressure sensor retraining on equipped vehicles.

• Suspension: Front and rear strut disassembly, hub and bearing replacement, control-arm bushing press work, and wheel alignment.

• Engine repair: Step-by-step engine removal and internal repair procedures, including cylinder-head and rotating-assembly work, timing-chain service on the DOHC V6, and timing-belt service on the SOHC V6.

• Automatic transaxle: 42LE overhaul, hydraulic pressure and clutch air tests, valve-body service, and Quick Learn adaptation.

• Brakes and ABS: Caliper overhaul, parking-brake adjustment, and DRBIII-assisted bleeding for the Teves Mark20e system.

• Fault isolation: DRBIII tests for powertrain, transmission, body electronics, and ABS faults, with diagnostic trouble code charts, connector pinouts, and circuit schematics.

Written for professional automotive technicians, the service manual is paired with diagnostic procedures that call for a DRBIII scan tool and procedure-specific test equipment.

Engine, Fuel, and Cooling Service

Compression and cylinder leakage tests help distinguish a sealing problem from other causes of poor running before internal engine work. The engine chapters cover cylinder-head inspection, valve and seat work, bearing-clearance checks, and piston-ring inspection. The 3.5L timing-belt section warns that incorrect camshaft or crankshaft rotation can damage valves or pistons.

Fuel-system coverage includes pressure testing and fuel pump module replacement. Cooling procedures cover leak testing, coolant aeration, refill and bleeding, and water-pump replacement.

Steering and 42LE Final Drive

The steering chapter distinguishes standard, firm-feel, and speed-proportional systems. It covers pump flow and pressure testing, steering-gear removal, and tie-rod service.

Final-drive setup covers pinion depth, differential bearing preload, and gear backlash. The transmission diagnostic book addresses limp-in operation, gear-ratio faults, speed sensors, and solenoid and pressure-switch circuits. It includes separate AutoStick tests where equipped. The Miller 8333 simulator and 8333-1 adapter help isolate wiring or controller faults from transaxle faults. The Valve Body—Exploded illustration identifies internal components, and the Solenoid Application Chart shows which solenoids are used in each gear.

NGC, Body Electronics, and Wiring

The 2002 Next Generation Controller (NGC) combines engine and transmission control in one PCM. Powertrain diagnostics cover no-start conditions, misfires, fuel-delivery faults, and EVAP leaks. They also cover module-replacement verification and Sentry Key Immobilizer Module and key programming. PCM connector procedures specify the Miller 8815 pinout box and 3638 terminal-release tool to avoid damaging terminals or the harness.

Body diagnostics cover PCI bus communication, airbag circuits, power locks, and wipers. Manual and Automatic Temperature Control have separate tests for blend, mode, and recirculation door faults. The service manual covers heater-core and evaporator replacement and gives body opening dimensions and weld, sealer, and structural adhesive locations.

Group 8W includes Fuel/Ignition (8W-30), Antilock Brakes (8W-35), Air Conditioning–Heater (8W-42), and Connector Pin-Outs (8W-80). The service chapters also provide torque tables, alignment data, wear limits, and Mopar fluid and grease specifications, including the different lubricants for the 42LE transaxle and differential sumps.

Review all factory safety protocols before working on loaded suspension springs, supporting the vehicle, or servicing braking components.

Sample Compression and Transaxle Fill Specifications

For both V6 engines, the manual gives a cranking compression guideline of at least 100 psi (689 kPa) and a maximum 25% difference between cylinders, with the engine at normal operating temperature and the throttle fully open.

The 42LE capacity table lists an estimated service fill of 4.5 qt. (4.3 L) and an overhaul fill of 9.3 qt. (8.8 L) with the torque converter empty.