2002 Dodge Intrepid SE, ES, R/T Service Manual (P/N 81-270-02027)

• Covers 2002 Dodge Intrepid four-door sedans with 2.7L DOHC or 3.5L SOHC V6 engines within Chrysler/Dodge LH-series service documentation.
• Front and rear suspension repair covers strut disassembly, hub and bearing replacement, control-arm bushing press work, and wheel alignment.
• Engine procedures extend to removal, cylinder-head and rotating-assembly repair, with 2.7L timing-chain and 3.5L timing-belt service.
• Details 42LE four-speed electronic automatic transaxle overhaul, hydraulic pressure and clutch air tests, valve-body service, and Quick Learn adaptation.
• Brake coverage includes caliper overhaul, parking-brake adjustment, and Teves Mark20e ABS, with and without traction control, plus scan-tool-assisted bleeding.
• Separate diagnostic manuals support DRBIII fault isolation for powertrain, transmission, body electronics, and ABS, with DTC tests, connector pinouts, and schematics.

The set contains 2,990 pages across seven PDF files. The Service Manual is a 1,707-page PDF; Body Diagnostics adds 666 pages and Gas Powertrain Diagnostics adds 372. Transmission Diagnostics contains 194 pages, and Chassis Diagnostics contains 48. A separate two-page title/foreword file and one-page navigation file complete the set.

Shared LH-platform coverage also includes the Chrysler 300M and Concorde. VIN and body-code decoding identify the model year, car line, engine, and transaxle configuration.

Component and Systems Documentation

Separate chapters break down the fuel system, cooling, and drivetrain. Cooling coverage includes leak testing, aeration/deaeration diagnosis, refill and bleeding procedures, and water-pump replacement. Steering sections distinguish standard, firm-feel, and speed-proportional systems, with pump flow/pressure testing, steering-gear removal, and tie-rod service.

Engine diagnosis covers compression and cylinder leakage tests before internal repair. Cylinder-head inspection, valve and seat work, bearing-clearance checks, and piston-ring inspection go beyond routine maintenance. The 3.5L timing section explains how incorrect crankshaft/camshaft rotation can damage valves or pistons.

The transaxle chapter also documents final-drive pinion-depth setup, differential bearing preload, and gear backlash. Its companion diagnostic book addresses limp-in operation, gear-ratio faults, speed sensors, and solenoid/pressure-switch circuits. AutoStick-equipped systems have their own tests.

2002 NGC Electronics and Body Diagnostics

For 2002, the manuals describe the Next Generation Controller (NGC), which combines engine and transmission control in one PCM. Coverage includes module-replacement verification and Sentry Key Immobilizer Module/key programming. Powertrain troubleshooting addresses no-start conditions, misfires, fuel-delivery faults, and EVAP leak detection.

The scan-tool tests and adaptations are written for the DRBIII, with additional test equipment specified by procedure. The transmission book describes the Miller 8333 simulator and 8333-1 adapter for isolating wiring/controller faults from transaxle faults. PCM connector work specifies the 8815 pinout box and 3638 terminal-removal tool; improper probing or terminal release can damage connector terminals and the harness.

Body troubleshooting covers PCI-bus communication failures, airbag circuits, power locks, and wipers. Manual and Automatic Temperature Control systems are treated separately, including blend-, mode-, and recirculation-door actuator faults. Mechanical HVAC work extends to heater-core and evaporator replacement. Body-structure references provide opening dimensions and weld, sealer, and structural-adhesive locations for body repair.

Wiring Diagrams and Technical Specifications

Group 8W provides wiring diagrams for Fuel/Ignition (8W-30), Antilock Brakes (8W-35), and Air Conditioning–Heater (8W-42). Connector Pin-Outs (8W-80) support terminal identification. The Valve Body—Exploded illustration supports transaxle repair, while the transmission diagnostic manual’s Solenoid Application Chart provides a gear-by-gear reference.

Torque tables, alignment data, fluid capacities, wear limits, and electrical test specifications accompany the repair information. The lubrication section defines Mopar-approved fluids and grease types, including the different lubricants required by the 42LE’s separate transmission and differential sumps.

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