2002 Dodge Caravan Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Product Type: Service Repair Manual Codes Platform Code: NS (Third Generation) 👋 Introduction Market Position Category: Minivan Target Audience: Families, fleet operators, DIY enthusiasts, professional mechanics Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Oldsmobile Silhouette, Buick GL8 Key Features Vehicle Appeal: Spacious interior, comfortable ride, versatile seating configurations, availability of all-wheel drive (on some models, though less common for 2002) Manual Value Proposition Benefit: Empowers owners to perform maintenance and repairs, saving money and ensuring longevity of the vehicle 📋 Manual Details Coverage Areas Primary Coverage: All aspects of service, repair, diagnosis, and maintenance Trim Levels: SE, ES, Sport Page Count Estimated Pages: Approximately 1500-2000 pages (typical for comprehensive factory manuals) Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical (3.3L V6, 3.8L V6), Fuel System, Exhaust System, Ignition System, Cooling System, Lubrication System, Engine Control Systems (PCM/ECU) Transmission: Automatic Transmissions (41TE, 42LE), Torque Converter, Shifter Linkage, Transmission Control Module (TCM) Drivetrain: Front Wheel Drive (FWD), Axles, CV Joints, Wheel Bearings Suspension: Front Suspension (MacPherson Struts), Rear Suspension (Torsion Beam Axle), Shock Absorbers, Springs, Control Arms, Bushings Brakes: Front Disc Brakes, Rear Drum Brakes, Anti-lock Braking System (ABS), Parking Brake Steering: Power Rack and Pinion Steering System, Steering Column, Tie Rods Electrical: Battery, Charging System, Starting System, Lighting System, Fuses and Relays, Wiring Diagrams, Instrument Panel, Power Accessories (Windows, Locks, Mirrors) HVAC: Heating, Ventilation, Air Conditioning (A/C) System, Blower Motor, Condenser, Evaporator, Refrigerant, Controls Body: Exterior Body Panels, Doors, Hood, Liftgate, Interior Trim, Glass, Seats, Body Sealing Restraint Systems: Airbags, Seatbelts, Occupant Restraint Controller (ORC) Procedures Included Maintenance: Oil Changes, Filter Replacements (Oil, Air, Fuel, Cabin), Spark Plug Replacement, Fluid Checks and Top-offs, Belt Inspections and Replacement, Tire Rotation and Balancing Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs) P-codes and B-codes, Power Flow Charts, Diagnostic Scan Tool Procedures Repair: Engine Overhaul, Transmission Repair/Rebuild, Brake System Overhaul, Suspension Component Replacement, Electrical Component Replacement, HVAC System Servicing, Body Panel Repair/Replacement Recalibration: Throttle Body Calibration, Wheel Speed Sensor Reset (ABS), Steering Angle Sensor Calibration Specifications: Torque Specifications for all fasteners, Diagnostic Specifications, Clearance Specifications, Alignment Specifications Technical Depth Depth: Comprehensive factory-level detail suitable for professional technicians and advanced DIYers Diagrams Quality: High-quality, detailed diagrams, schematics, and illustrations Troubleshooting: In-depth troubleshooting procedures, flowcharts, and wiring diagrams for electrical systems Rebuild Procedures: Detailed instructions for engine and transmission disassembly, inspection, repair, and reassembly 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text for quick access to information Printability: Printable pages for on-the-job use Print Quality Quality: High-resolution scans ensuring clarity of text and diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1: 3.3L OHV V6 (EGA) Engine 1 Displacement: 3301 cc (201.5 cu in) Engine 1 Horsepower: 158 hp @ 4800 rpm Engine 1 Torque: 203 lb-ft @ 3200 rpm Optional Engine Engine 2: 3.8L OHV V6 (L32) Engine 2 Displacement: 3778 cc (230.5 cu in) Engine 2 Horsepower: 180 hp @ 4600 rpm Engine 2 Torque: 235 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Ignition System Ignition Type: Distributorless Ignition System (DIS) with coil-on-plug or coil pack arrangement Engine Management ECM Type: Powertrain Control Module (PCM) 🔧 Transmission Standard Transmission Type 1: 4-speed Automatic (41TE/42LE) Optional Transmission Type 2: N/A (Automatic was standard across all trims for 2002) Features Transmission Control: Electronically Controlled Transmission (ECT) Fluid Specifications Transmission Fluid: ATF+4 (Chrysler Material Standard MS-9602) Fluid Capacity Transmission Fluid Capacity: Approximately 7.7 quarts (7.3 liters) for 3.3L, 9.3 quarts (8.8 liters) for 3.8L (dry fill) 📐 Dimensions Exterior Wheelbase: 112.1 inches (2847 mm) Length: 187.4 inches (4760 mm) Width: 72.0 inches (1829 mm) Height: 66.1 inches (1679 mm) Weights Curb Weight Min: Approximately 3830 lbs (1737 kg) for 3.3L SE Curb Weight Max: Approximately 4090 lbs (1855 kg) for 3.8L ES Cargo Cargo Volume Behind 3Rd Row: Approximately 15.0 cu ft (425 liters) Cargo Volume Behind 2Nd Row: Approximately 47.7 cu ft (1351 liters) Cargo Volume Behind 1St Row: Approximately 115.9 cu ft (3282 liters) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 stars (out of 5) - 2002 model year NHTSA Front Impact Passenger: 4 stars (out of 5) - 2002 model year NHTSA Side Impact Front Seat: 4 stars (out of 5) - 2002 model year NHTSA Side Impact Rear Seat: 5 stars (out of 5) - 2002 model year IIHS Side Impact: Acceptable - 2002 model year Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System Passive Features Airbags Front: Standard Driver and Front Passenger Airbags Airbags Side: Optional Side Impact Airbags (front...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Product Type:

Service Repair Manual

Codes

Platform Code:

NS (Third Generation)

👋 Introduction

Market Position

Category:

Minivan

Target Audience:

Families, fleet operators, DIY enthusiasts, professional mechanics

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Oldsmobile Silhouette, Buick GL8

Key Features

Vehicle Appeal:

Spacious interior, comfortable ride, versatile seating configurations, availability of all-wheel drive (on some models, though less common for 2002)

Manual Value Proposition

Benefit:

Empowers owners to perform maintenance and repairs, saving money and ensuring longevity of the vehicle

📋 Manual Details

Coverage Areas

Primary Coverage:

All aspects of service, repair, diagnosis, and maintenance

Trim Levels:

SE, ES, Sport

Page Count

Estimated Pages:

Approximately 1500-2000 pages (typical for comprehensive factory manuals)

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical (3.3L V6, 3.8L V6), Fuel System, Exhaust System, Ignition System, Cooling System, Lubrication System, Engine Control Systems (PCM/ECU)

Transmission:

Automatic Transmissions (41TE, 42LE), Torque Converter, Shifter Linkage, Transmission Control Module (TCM)

Drivetrain:

Front Wheel Drive (FWD), Axles, CV Joints, Wheel Bearings

Suspension:

Front Suspension (MacPherson Struts), Rear Suspension (Torsion Beam Axle), Shock Absorbers, Springs, Control Arms, Bushings

Brakes:

Front Disc Brakes, Rear Drum Brakes, Anti-lock Braking System (ABS), Parking Brake

Steering:

Power Rack and Pinion Steering System, Steering Column, Tie Rods

Electrical:

Battery, Charging System, Starting System, Lighting System, Fuses and Relays, Wiring Diagrams, Instrument Panel, Power Accessories (Windows, Locks, Mirrors)

HVAC:

Heating, Ventilation, Air Conditioning (A/C) System, Blower Motor, Condenser, Evaporator, Refrigerant, Controls

Body:

Exterior Body Panels, Doors, Hood, Liftgate, Interior Trim, Glass, Seats, Body Sealing

Restraint Systems:

Airbags, Seatbelts, Occupant Restraint Controller (ORC)

Procedures Included

Maintenance:

Oil Changes, Filter Replacements (Oil, Air, Fuel, Cabin), Spark Plug Replacement, Fluid Checks and Top-offs, Belt Inspections and Replacement, Tire Rotation and Balancing

Diagnostics:

Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs) P-codes and B-codes, Power Flow Charts, Diagnostic Scan Tool Procedures

Repair:

Engine Overhaul, Transmission Repair/Rebuild, Brake System Overhaul, Suspension Component Replacement, Electrical Component Replacement, HVAC System Servicing, Body Panel Repair/Replacement

Recalibration:

Throttle Body Calibration, Wheel Speed Sensor Reset (ABS), Steering Angle Sensor Calibration

Specifications:

Torque Specifications for all fasteners, Diagnostic Specifications, Clearance Specifications, Alignment Specifications

Technical Depth

Depth:

Comprehensive factory-level detail suitable for professional technicians and advanced DIYers

Diagrams Quality:

High-quality, detailed diagrams, schematics, and illustrations

Troubleshooting:

In-depth troubleshooting procedures, flowcharts, and wiring diagrams for electrical systems

Rebuild Procedures:

Detailed instructions for engine and transmission disassembly, inspection, repair, and reassembly

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick access to information

Printability:

Printable pages for on-the-job use

Print Quality

Quality:

High-resolution scans ensuring clarity of text and diagrams

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.3L OHV V6 (EGA)

Engine 1 Displacement:

3301 cc (201.5 cu in)

Engine 1 Horsepower:

158 hp @ 4800 rpm

Engine 1 Torque:

203 lb-ft @ 3200 rpm

Optional Engine

Engine 2:

3.8L OHV V6 (L32)

Engine 2 Displacement:

3778 cc (230.5 cu in)

Engine 2 Horsepower:

180 hp @ 4600 rpm

Engine 2 Torque:

235 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with coil-on-plug or coil pack arrangement

Engine Management

ECM Type:

Powertrain Control Module (PCM)

🔧 Transmission

Standard

Transmission Type 1:

4-speed Automatic (41TE/42LE)

Optional

Transmission Type 2:

N/A (Automatic was standard across all trims for 2002)

Features

Transmission Control:

Electronically Controlled Transmission (ECT)

Fluid Specifications

Transmission Fluid:

ATF+4 (Chrysler Material Standard MS-9602)

Fluid Capacity

Transmission Fluid Capacity:

Approximately 7.7 quarts (7.3 liters) for 3.3L, 9.3 quarts (8.8 liters) for 3.8L (dry fill)

📐 Dimensions

Exterior

Wheelbase:

112.1 inches (2847 mm)

Length:

187.4 inches (4760 mm)

Width:

72.0 inches (1829 mm)

Height:

66.1 inches (1679 mm)

Weights

Curb Weight Min:

Approximately 3830 lbs (1737 kg) for 3.3L SE

Curb Weight Max:

Approximately 4090 lbs (1855 kg) for 3.8L ES

Cargo

Cargo Volume Behind 3Rd Row:

Approximately 15.0 cu ft (425 liters)

Cargo Volume Behind 2Nd Row:

Approximately 47.7 cu ft (1351 liters)

Cargo Volume Behind 1St Row:

Approximately 115.9 cu ft (3282 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 stars (out of 5) - 2002 model year

NHTSA Front Impact Passenger:

4 stars (out of 5) - 2002 model year

NHTSA Side Impact Front Seat:

4 stars (out of 5) - 2002 model year

NHTSA Side Impact Rear Seat:

5 stars (out of 5) - 2002 model year

IIHS Side Impact:

Acceptable - 2002 model year

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System

Passive Features

Airbags Front:

Standard Driver and Front Passenger Airbags

Airbags Side:

Optional Side Impact Airbags (front seats)

Seat Belts:

Three-point seat belts in all seating positions, front seat pretensioners

💡 Technology Features

Infotainment

Audio System:

Optional AM/FM stereo with CD player, cassette player, and premium speaker systems. Rear entertainment system options available on higher trims.

Driver Assistance

Cruise Control:

Standard cruise control

Connectivity

Auxiliary Input:

Not commonly equipped with auxiliary audio input or USB ports in this era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type (consult owner's manual for precise recommendations).

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Platinum-tipped spark plugs: 100,000 miles (160,000 km). Check manual for specific type.

Coolant Change:

Every 30,000-60,000 miles (48,000-96,000 km) or 3-5 years, depending on coolant type.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km) under normal use. More frequently for severe use (towing, stop-and-go traffic).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API certified)

Engine Oil Capacity:

3.3L V6: 3.75 quarts (3.5 liters) with filter. 3.8L V6: 4.5 quarts (4.3 liters) with filter.

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue or equivalent.

Known Issues

Common Problems Powertrain:

Head gasket leaks (particularly on 3.8L), transmission solenoid failures, coolant leaks from plastic intake manifold gaskets (pre-2001, but can still occur).

Common Problems Electrical:

Faulty power window regulators, intermittent instrument cluster issues, failure of the Totally Integrated Power Module (TIPM) and related relays.

Common Problems Suspension Steering:

Worn front wheel bearings, premature failure of tie rod ends and ball joints, strut mount noise.

Common Problems HVAC:

A/C compressor clutch failure, evaporator leaks, blend door actuator malfunctions.

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan in 1984, establishing a benchmark for family transport.

Model Evolution

Generation:

Third Generation (NS) - 1996-2000 (facelifted for 2001 as RG)

2002 Model Year Updates:

For 2002, the Caravan received minor updates, building on the refreshed design from 2001. The 'RG' platform continued. The available powertrains (3.3L and 3.8L V6) remained largely the same.

Production

Assembly Location:

Windsor, Ontario, Canada (Windsor Assembly Plant)

🏆 Awards & Recognition

Recognitions

Ward Auto Ten Best Engines:

The 3.8L V6 engine has historically been recognized by Ward's AutoWorld as one of the ten best engines in North America in previous years for its smoothness and reliability.

Ratings

Consumer Reports Reliability:

Reliability ratings for the 2002 Dodge Caravan can vary, but common issues like head gaskets and transmissions are often cited. Manual provides guidance on addressing these.