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2002 Dodge Caravan Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Vehicle Type: Minivan 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families, fleet operators, automotive repair shops Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture Key Features Vehicle Strengths: Spacious interior, versatile seating configurations, practical for family transport, often equipped with Stow 'n Go seating (later models, but foundational to the Caravan's appeal) Manual Value Benefit To Owner: Empowers owners to perform maintenance and repairs, saving money and ensuring vehicle longevity Benefit To Technician: Provides accurate, manufacturer-specific procedures for efficient and correct repairs 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 2002 Dodge Caravan Engine Coverage: 2.4L I4, 3.3L V6, 3.8L V6 Transmission Coverage: Automatic Transmissions (4-speed) Electrical Coverage: Extensive diagnosis and repair of all electrical systems, including wiring diagrams Chassis Coverage: Suspension, steering, brakes, exhaust, fuel system Body Coverage: Body and chassis repair, doors, interior trim, climate control Page Count Estimated Page Count: ~2000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete teardown, inspection, and reassembly of all engine components (pistons, rings, valves, camshafts, crankshafts, cylinder heads, blocks) Engine Performance: Fuel injection systems, ignition systems, emissions control systems, turbocharging (if applicable), engine control module (ECM) operation and diagnostics Transmission Overhaul: Detailed procedures for automatic transmission repair, including valve bodies, torque converters, clutch packs, planetary gears Braking System: Hydraulic system diagnosis, ABS operation, brake pad/rotor replacement, caliper service, parking brake adjustments Suspension Steering: Struts, shocks, control arms, ball joints, tie rods, power steering system, wheel alignment procedures HVAC System: Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser service, heater core replacement Body Electrical: Lighting, power windows, power locks, door mechanisms, sunroof operation, instrument cluster diagnostics Diagnostic Troubleshooting: Systematic approach to diagnosing common and intermittent faults using diagnostic trouble codes (DTCs) and scan tool data Procedures Included Maintenance: Oil changes, filter replacements, tune-ups, fluid checks and replacements, belt and hose inspections Repair: Component replacement, engine rebuilds, transmission rebuilds, suspension and brake repairs, electrical component repair Troubleshooting: Step-by-step diagnostic guides for various symptoms and fault conditions Diagnostics: In-depth diagnostic procedures for all major vehicle systems, including PCM/ECM diagnostic codes Technical Depth Depth: Factory-level detail, suitable for professional technicians and advanced DIYers Diagnostics Level: Advanced diagnostic strategies, including sensor data interpretation and component testing Rebuild Procedures: Complete rebuild procedures for major mechanical components like engines and transmissions 📊 Manual Specifications File Format Format: Searchable PDF Print Quality Resolution: High-resolution, suitable for on-screen viewing and printing Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) Searchability Search Functionality: Full text search capability for quick information retrieval ⚙️ Engine Specifications Primary Engine Engine 1: 2.4L DOHC Inline-4 ( = 2378 cc) Engine 1 Power: 150 hp @ 5800 rpm Engine 1 Torque: 170 lb-ft @ 4000 rpm Optional Engine Engine 2: 3.3L OHV V6 ( = 3301 cc) Engine 2 Power: 180 hp @ 5000 rpm Engine 2 Torque: 205 lb-ft @ 3600 rpm Engine 3: 3.8L OHV V6 ( = 3778 cc) Engine 3 Power: 200 hp @ 5200 rpm Engine 3 Torque: 232 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Ignition System Ignition Type: Distributorless Ignition System (DIS) with individual ignition coils Emission Controls Emission System: Catalytic converter, Oxygen sensors (O2S), EGR (Exhaust Gas Recirculation) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transmission (41TE) Optional Optional Transmission: Not typically applicable for this year; primarily automatic Features Transmission Fluid Type: ATF+4 (Mopar) Transmission Fluid Capacity: Approx. 11.0 quarts (10.4 liters) - check manual for precise refill amount Transmission Control: Electronically controlled with overdrive 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 189.8 inches (4821 mm) Width: 72.0 inches (1829 mm) Height: 66.4 inches (1687 mm) Cargo Cargo Volume Behind 3Rd Row: Approx. 32.0 cubic feet (0.91 cubic meters) Cargo Volume Behind 2Nd Row: Approx. 76.5 cubic feet (2.17 cubic meters) Cargo Volume Max: Approx. 140.5 cubic feet (3.98 cubic meters) Weights Curb Weight Min: Approx. 3800 lbs (1724 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5600 lbs (2540 kg) - varies by engine and configuration 🛡️ Safety Features Ratings NHTSA Frontal Driver: Good (for 2002 model year, depending on specific tests) NHTSA Frontal Passenger: Good (for 2002 model year, depending on specific tests) NHTSA Side Impact Driver: Acceptable/Good (for 2002 model year, depending on specific tests) NHTSA Side Impact Rear Passenger: Acceptable/Good (for 2002 model year, depending on specific tests) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional traction control system Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front-seat side-impact airbags Seatbelts: 3-point seat belts for all seating positions, front seat pretensioners 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette...
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Type: Caravan
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Sku: 440354
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2002 Dodge Caravan Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2002
Vehicle Type:
Minivan
👋 Introduction
Market Position
Segment:
Mid-size Minivan
Target Audience:
Families, fleet operators, automotive repair shops
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Vehicle Strengths:
Spacious interior, versatile seating configurations, practical for family transport, often equipped with Stow 'n Go seating (later models, but foundational to the Caravan's appeal)
Manual Value
Benefit To Owner:
Empowers owners to perform maintenance and repairs, saving money and ensuring vehicle longevity
Benefit To Technician:
Provides accurate, manufacturer-specific procedures for efficient and correct repairs
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for the 2002 Dodge Caravan
Engine Coverage:
2.4L I4, 3.3L V6, 3.8L V6
Transmission Coverage:
Automatic Transmissions (4-speed)
Electrical Coverage:
Extensive diagnosis and repair of all electrical systems, including wiring diagrams
Chassis Coverage:
Suspension, steering, brakes, exhaust, fuel system
Body Coverage:
Body and chassis repair, doors, interior trim, climate control
Page Count
Estimated Page Count:
~2000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete teardown, inspection, and reassembly of all engine components (pistons, rings, valves, camshafts, crankshafts, cylinder heads, blocks)
Engine Performance:
Fuel injection systems, ignition systems, emissions control systems, turbocharging (if applicable), engine control module (ECM) operation and diagnostics
Transmission Overhaul:
Detailed procedures for automatic transmission repair, including valve bodies, torque converters, clutch packs, planetary gears
Braking System:
Hydraulic system diagnosis, ABS operation, brake pad/rotor replacement, caliper service, parking brake adjustments
Suspension Steering:
Struts, shocks, control arms, ball joints, tie rods, power steering system, wheel alignment procedures
HVAC System:
Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser service, heater core replacement
Body Electrical:
Lighting, power windows, power locks, door mechanisms, sunroof operation, instrument cluster diagnostics
Diagnostic Troubleshooting:
Systematic approach to diagnosing common and intermittent faults using diagnostic trouble codes (DTCs) and scan tool data
Procedures Included
Maintenance:
Oil changes, filter replacements, tune-ups, fluid checks and replacements, belt and hose inspections
Repair:
Component replacement, engine rebuilds, transmission rebuilds, suspension and brake repairs, electrical component repair
Troubleshooting:
Step-by-step diagnostic guides for various symptoms and fault conditions
Diagnostics:
In-depth diagnostic procedures for all major vehicle systems, including PCM/ECM diagnostic codes
Technical Depth
Depth:
Factory-level detail, suitable for professional technicians and advanced DIYers
Diagnostics Level:
Advanced diagnostic strategies, including sensor data interpretation and component testing
Rebuild Procedures:
Complete rebuild procedures for major mechanical components like engines and transmissions
📊 Manual Specifications
File Format
Format:
Searchable PDF
Print Quality
Resolution:
High-resolution, suitable for on-screen viewing and printing
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
Searchability
Search Functionality:
Full text search capability for quick information retrieval
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.4L DOHC Inline-4 ( = 2378 cc)
Engine 1 Power:
150 hp @ 5800 rpm
Engine 1 Torque:
170 lb-ft @ 4000 rpm
Optional Engine
Engine 2:
3.3L OHV V6 ( = 3301 cc)
Engine 2 Power:
180 hp @ 5000 rpm
Engine 2 Torque:
205 lb-ft @ 3600 rpm
Engine 3:
3.8L OHV V6 ( = 3778 cc)
Engine 3 Power:
200 hp @ 5200 rpm
Engine 3 Torque:
232 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with individual ignition coils
Emission Controls
Emission System:
Catalytic converter, Oxygen sensors (O2S), EGR (Exhaust Gas Recirculation)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transmission (41TE)
Optional
Optional Transmission:
Not typically applicable for this year; primarily automatic
Features
Transmission Fluid Type:
ATF+4 (Mopar)
Transmission Fluid Capacity:
Approx. 11.0 quarts (10.4 liters) - check manual for precise refill amount
Transmission Control:
Electronically controlled with overdrive
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
189.8 inches (4821 mm)
Width:
72.0 inches (1829 mm)
Height:
66.4 inches (1687 mm)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 32.0 cubic feet (0.91 cubic meters)
Cargo Volume Behind 2Nd Row:
Approx. 76.5 cubic feet (2.17 cubic meters)
Cargo Volume Max:
Approx. 140.5 cubic feet (3.98 cubic meters)
Weights
Curb Weight Min:
Approx. 3800 lbs (1724 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5600 lbs (2540 kg) - varies by engine and configuration
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
Good (for 2002 model year, depending on specific tests)
NHTSA Frontal Passenger:
Good (for 2002 model year, depending on specific tests)
NHTSA Side Impact Driver:
Acceptable/Good (for 2002 model year, depending on specific tests)
NHTSA Side Impact Rear Passenger:
Acceptable/Good (for 2002 model year, depending on specific tests)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional traction control system
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front-seat side-impact airbags
Seatbelts:
3-point seat belts for all seating positions, front seat pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and CD player options. Optional Infinity sound system.
Navigation:
Not commonly available or advanced in this model year; typically aftermarket units.
Driver Assistance
Cruise Control:
Standard or optional cruise control
Parking Sensors:
Optional rear parking assist sensors
Connectivity
Auxiliary Input:
Not typically equipped with standard aux-in or USB ports; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (consult manual for specific recommendations).
Engine Air Filter:
Replace every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Cabin Air Filter:
Replace every 12,000-15,000 miles (19,000-24,000 km) or annually.
Spark Plugs:
Replace at 100,000 miles (160,000 km) for platinum/iridium plugs (standard for most 2002 models).
Transmission Fluid Service:
Flush and replace every 60,000-100,000 miles (96,000-160,000 km) or as specified in the manual.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (for most conditions), SAE 10W-30 (in very mild temperatures). Consult owner's manual for exact spec based on engine.
Coolant Type:
Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, Orange (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 (or DOT 4 if specified).
Power Steering Fluid:
ATF+4 or specific Mopar power steering fluid.
Known Issues
Common Issues 1:
Transmission solenoid failures and torque converter issues (especially on higher mileage vehicles).
Common Issues 2:
Cracked exhaust manifolds (especially on V6 engines).
Common Issues 3:
Power door lock actuators and sliding door issues.
Common Issues 4:
Rear suspension sag or noise, often requiring replacement of springs or shocks.
Common Issues 5:
Evaporative emission control system (EVAP) leaks, often due to faulty vent valve or gas cap.
📚 Vehicle History
Brand Heritage
Dodge Heritage:
Dodge, a division of Chrysler (now Stellantis), has a long history of producing practical and powerful vehicles, including its significant contribution to the minivan segment.
Model Evolution
Minivan Origin:
The Dodge Caravan, along with its Plymouth Voyager counterpart, pioneered the minivan segment in the 1980s, revolutionizing family transportation.
Third Generation:
The 2002 model belongs to the third generation of the Dodge Caravan (1996-2007), which saw significant redesigns in styling and technology.
Production
Manufacturing Plant:
Primarily Windsor, Ontario, Canada and St. Louis, Missouri, USA.
Production Years
Model Run:
1984-2020 (Dodge Caravan/Grand Caravan nameplate)
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Consistently a top-selling minivan, recognized for its value and practicality.
Ratings
Consumer Reports Ratings:
Variable depending on year and specific components, often rated as average for predicted reliability in this era.
Certifications
Safety Certifications:
Meets all U.S. federal motor vehicle safety standards (FMVSS) for the 2002 model year.
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