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Dodge Caravan 2002 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Codes Chassis Code: RS Body Style 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size Minivan Target Audience For Manual: DIY mechanics, independent repair shops, fleet maintenance personnel Competitive Analysis Key Competitors 2002: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture Key Features Vehicle Selling Points: Spacious interior, versatile seating configurations, comfortable ride, family-oriented features Manual Value Proposition: Empowers owners to perform their own maintenance and repairs, saving significant costs compared to dealership or independent shop labor. 📋 Manual Details Coverage Areas Primary Coverage: 2002 Dodge Caravan Engine Variants Covered: 3.3L V6 (EGA), 3.8L V6 (GVA) Transmission Variants Covered: 4-speed Automatic (41TE, 42LE) Page Count Estimated Page Count: Approximately 2000+ pages (typical for WSM) Manual Type Manual Type: Workshop Service Manual (WSM) / Service Repair Manual Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, component testing, diagnosis, specifications Engine Performance: Fuel injection, ignition system, emissions control, exhaust system Transmission Mechanical: Overhaul, diagnostic procedures, valve body, torque converter Transmission Electronic: Transmission control module (TCM) diagnostics, solenoid testing, sensor data Brake System: Hydraulic system, ABS (Anti-lock Braking System) components and diagnosis, parking brake Suspension System: Front and rear suspension components, alignment procedures, shock absorber/strut replacement Steering System: Power steering system diagnosis and repair, steering column, tie rods Electrical System Charging: Alternator, battery, voltage regulator Electrical System Starting: Starter motor, starter solenoid, ignition switch Lighting System: Headlamps, tail lamps, interior lighting, bulb replacement HVAC System: Air conditioning, heating, ventilation, blower motor, refrigerant system Body And Chassis: Body panels, doors, hinges, latches, interior trim, chassis components Restraint Systems: Airbag system diagnosis and replacement, seat belts Power Accessories: Power windows, power locks, power mirrors, power seats Diagnostics: OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), scan tool usage Procedures Included Maintenance: Oil changes, fluid flushes, filter replacements, spark plug service, belt replacement Troubleshooting: Step-by-step diagnostic trees for common and complex issues Repair: Component removal and installation, part replacement, adjustments Overhaul: Engine and transmission rebuilding procedures Electrical Diagnosis: Wiring diagrams, circuit testing, component testing Diagnostic Tool Usage: Information on using diagnostic scanners and specific testing equipment Technical Depth Depth Of Information: Comprehensive: Covers routine maintenance to complete engine and transmission overhauls, including detailed diagnostics and repair procedures. Diagnostic Focus: Advanced diagnostics, including sensor data interpretation and pinpoint testing. Repair Detail: Detailed step-by-step repair instructions with torque specifications and critical measurements. 📊 Manual Specifications File Format Digital File Type: PDF (Portable Document Format) Print Quality Scanned Resolution: High-resolution scans ensuring legibility of text and diagrams. Binding Type Digital Format Advantage: Searchable text, easy navigation via bookmarks and hyperlinks (if digitally created). Paper Type Original Manual Paper: Typically printed on durable, heavy-duty paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code 1: EGA Engine Type 1: 3.3L SOHC V6 Displacement 1: 3301 cc (201.5 cubic inches) Bore X Stroke 1: 93.0 mm x 78.0 mm (3.66 in x 3.07 in) Compression Ratio 1: 9.0:1 Horsepower 1: 158 hp @ 4600 rpm (SAE Net) Torque 1: 195 lb-ft @ 3200 rpm (SAE Net) Optional Engine Engine Code 2: GVA Engine Type 2: 3.8L SOHC V6 Displacement 2: 3778 cc (230.5 cubic inches) Bore X Stroke 2: 93.0 mm x 90.9 mm (3.66 in x 3.58 in) Compression Ratio 2: 9.0:1 Horsepower 2: 180 hp @ 4400 rpm (SAE Net) Torque 2: 235 lb-ft @ 3200 rpm (SAE Net) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane recommended Ignition System Ignition Type: Distributorless Ignition System (DIS) with individual ignition coils. 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle Transmission Codes: 41TE (3.3L), 42LE (3.8L) Optional Manual Transmission Availability: Not available for 2002 Dodge Caravan. Features Overdrive: Yes, all gears (including 4th gear) Torque Converter Lockup: Yes, electronically controlled. Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid) Transmission Fluid Capacity: Approximately 9.5 - 11.5 quarts (9.0 - 10.9 liters) for complete refill. 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Overall Length: 189.4 inches (4811 mm) Overall Width: 72.0 inches (1829 mm) Overall Height: 68.4 inches (1737 mm) Weights Curb Weight Approximate: 3,800 - 4,100 lbs (1724 - 1860 kg), varies by configuration Gross Vehicle Weight Rating Gvwr: Approx. 5,600 lbs (2540 kg) Cargo Maximum Cargo Volume: Approx. 147.5 cu ft (4176 liters) with rear seats removed. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 out of 5 stars (2002 Model Year) NHTSA Front Impact Passenger: 4 out of 5 stars (2002 Model Year) IIHS Frontal Offset Rating: Good (for most models within this generation, check specific year ratings) Active Features ABS: Standard on most models, 4-wheel disc brakes available. Passive Features Airbags: Standard front airbags for driver and passenger. Optional side airbags may be available on higher trims. Seat Belts: All...
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Dodge Caravan 2002 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2002
Codes
Chassis Code:
RS Body Style
👋 Introduction
Market Position
Vehicle Segment:
Compact/Mid-size Minivan
Target Audience For Manual:
DIY mechanics, independent repair shops, fleet maintenance personnel
Competitive Analysis
Key Competitors 2002:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Vehicle Selling Points:
Spacious interior, versatile seating configurations, comfortable ride, family-oriented features
Manual Value Proposition:
Empowers owners to perform their own maintenance and repairs, saving significant costs compared to dealership or independent shop labor.
📋 Manual Details
Coverage Areas
Primary Coverage:
2002 Dodge Caravan
Engine Variants Covered:
3.3L V6 (EGA), 3.8L V6 (GVA)
Transmission Variants Covered:
4-speed Automatic (41TE, 42LE)
Page Count
Estimated Page Count:
Approximately 2000+ pages (typical for WSM)
Manual Type
Manual Type:
Workshop Service Manual (WSM) / Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures, component testing, diagnosis, specifications
Engine Performance:
Fuel injection, ignition system, emissions control, exhaust system
Transmission Mechanical:
Overhaul, diagnostic procedures, valve body, torque converter
Transmission Electronic:
Transmission control module (TCM) diagnostics, solenoid testing, sensor data
Brake System:
Hydraulic system, ABS (Anti-lock Braking System) components and diagnosis, parking brake
Suspension System:
Front and rear suspension components, alignment procedures, shock absorber/strut replacement
Steering System:
Power steering system diagnosis and repair, steering column, tie rods
Electrical System Charging:
Alternator, battery, voltage regulator
Electrical System Starting:
Starter motor, starter solenoid, ignition switch
Lighting System:
Headlamps, tail lamps, interior lighting, bulb replacement
HVAC System:
Air conditioning, heating, ventilation, blower motor, refrigerant system
Body And Chassis:
Body panels, doors, hinges, latches, interior trim, chassis components
Restraint Systems:
Airbag system diagnosis and replacement, seat belts
Power Accessories:
Power windows, power locks, power mirrors, power seats
Diagnostics:
OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), scan tool usage
Procedures Included
Maintenance:
Oil changes, fluid flushes, filter replacements, spark plug service, belt replacement
Troubleshooting:
Step-by-step diagnostic trees for common and complex issues
Repair:
Component removal and installation, part replacement, adjustments
Overhaul:
Engine and transmission rebuilding procedures
Electrical Diagnosis:
Wiring diagrams, circuit testing, component testing
Diagnostic Tool Usage:
Information on using diagnostic scanners and specific testing equipment
Technical Depth
Depth Of Information:
Comprehensive: Covers routine maintenance to complete engine and transmission overhauls, including detailed diagnostics and repair procedures.
Diagnostic Focus:
Advanced diagnostics, including sensor data interpretation and pinpoint testing.
Repair Detail:
Detailed step-by-step repair instructions with torque specifications and critical measurements.
📊 Manual Specifications
File Format
Digital File Type:
PDF (Portable Document Format)
Print Quality
Scanned Resolution:
High-resolution scans ensuring legibility of text and diagrams.
Binding Type
Digital Format Advantage:
Searchable text, easy navigation via bookmarks and hyperlinks (if digitally created).
Paper Type
Original Manual Paper:
Typically printed on durable, heavy-duty paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA
Engine Type 1:
3.3L SOHC V6
Displacement 1:
3301 cc (201.5 cubic inches)
Bore X Stroke 1:
93.0 mm x 78.0 mm (3.66 in x 3.07 in)
Compression Ratio 1:
9.0:1
Horsepower 1:
158 hp @ 4600 rpm (SAE Net)
Torque 1:
195 lb-ft @ 3200 rpm (SAE Net)
Optional Engine
Engine Code 2:
GVA
Engine Type 2:
3.8L SOHC V6
Displacement 2:
3778 cc (230.5 cubic inches)
Bore X Stroke 2:
93.0 mm x 90.9 mm (3.66 in x 3.58 in)
Compression Ratio 2:
9.0:1
Horsepower 2:
180 hp @ 4400 rpm (SAE Net)
Torque 2:
235 lb-ft @ 3200 rpm (SAE Net)
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane recommended
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with individual ignition coils.
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle
Transmission Codes:
41TE (3.3L), 42LE (3.8L)
Optional
Manual Transmission Availability:
Not available for 2002 Dodge Caravan.
Features
Overdrive:
Yes, all gears (including 4th gear)
Torque Converter Lockup:
Yes, electronically controlled.
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid)
Transmission Fluid Capacity:
Approximately 9.5 - 11.5 quarts (9.0 - 10.9 liters) for complete refill.
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Overall Length:
189.4 inches (4811 mm)
Overall Width:
72.0 inches (1829 mm)
Overall Height:
68.4 inches (1737 mm)
Weights
Curb Weight Approximate:
3,800 - 4,100 lbs (1724 - 1860 kg), varies by configuration
Gross Vehicle Weight Rating Gvwr:
Approx. 5,600 lbs (2540 kg)
Cargo
Maximum Cargo Volume:
Approx. 147.5 cu ft (4176 liters) with rear seats removed.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 out of 5 stars (2002 Model Year)
NHTSA Front Impact Passenger:
4 out of 5 stars (2002 Model Year)
IIHS Frontal Offset Rating:
Good (for most models within this generation, check specific year ratings)
Active Features
ABS:
Standard on most models, 4-wheel disc brakes available.
Passive Features
Airbags:
Standard front airbags for driver and passenger. Optional side airbags may be available on higher trims.
Seat Belts:
All seating positions equipped with three-point seat belts. Front seat belts with pretensioners.
💡 Technology Features
Infotainment
Radio Options:
AM/FM stereo with CD player, cassette player. Optional premium audio systems.
Rear Seat Entertainment:
Optional DVD entertainment system with integrated screen available on some trims.
Driver Assistance
Cruise Control:
Standard on most trims.
Parking Assistance:
Rear parking assist sensors were an optional feature.
Connectivity
Auxiliary Inputs:
Not typically equipped with standard auxiliary input jacks in this era. Aftermarket solutions may be available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions. Consult manual for specific recommendations.
Engine Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Typically every 100,000 miles (160,000 km) for original equipment platinum or iridium plugs. Consult manual for specific plug type and interval.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km). Crucial for longevity; consult manual for exact interval and procedure.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Certified)
Engine Oil Capacity:
3.8 quarts (3.6 liters) for 3.3L, 4.0 quarts (3.8 liters) for 3.8L (without filter change). Consult manual for capacity with filter.
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, blue color.
Coolant Capacity:
Approx. 13.1 quarts (12.4 liters)
Known Issues
Common Problems Engine:
Intake manifold gasket leaks, occasional head gasket issues (especially on higher mileage examples), oil filter adapter gasket leaks.
Common Problems Transmission:
Erratic shifting, delayed engagement, or transmission slipping can occur, often related to internal wear or solenoid issues. ATF+4 is critical.
Common Problems Electrical:
Faulty power window regulators, power door lock actuators, and sometimes issues with the ignition switch or instrument cluster.
Common Problems Suspension Steering:
Worn tie rod ends, ball joints, and control arm bushings leading to clunking noises or steering looseness.
Common Problems HVAC:
Blend door actuator failures causing improper air temperature control or vent selection issues.
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan/Voyager in the mid-1980s, setting a benchmark for family transport.
Model Evolution
Generation:
Second Generation (1996-2000) - This 2002 model is part of the facelifted second generation, often referred to as the 'RS' body style.
2002 Model Year Updates:
Minor styling updates and feature enhancements compared to earlier models in this generation. Introduction of optional DVD entertainment system.
Production
Manufacturing Location:
Windsor, Ontario, Canada
Production Span For Generation:
1996-2000, with significant facelifts continuing through 2007.
🏆 Awards & Recognition
Recognitions
Initial Reception:
Dodge Caravan and its siblings were consistently praised for their practicality, interior space, and family-friendly features.
Automotive Journal Awards:
Often featured on lists of recommended vehicles by automotive publications for its segment.
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