Dodge Caravan 2002 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Codes Platform: RS 👋 Introduction Market Position Segment: Minivan Positioning Statement: The Dodge Caravan was a cornerstone of the minivan segment, offering practicality, versatility, and value for families and businesses. This manual provides the essential technical data needed to maintain and repair these reliable vehicles. Competitive Analysis Key Competitors: Chrysler Town & Country, Plymouth Voyager, Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna Key Features Vehicle Appeal: Spacious interior, flexible seating configurations, family-friendly features, wide range of powertrain options. Manual Advantage: Directly sourced from factory data, ensuring accuracy and completeness for all repair and maintenance tasks. 📋 Manual Details Coverage Areas Trims Covered: All trims Engine Variants Covered: 2.5L Diesel, 2.8L Diesel, 2.4L 4-Cylinder, 3.3L V6, 3.8L V6 Page Count Estimated Pages: Over 2000 (typical for a complete factory workshop manual) Manual Type Type: Factory Service Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Diesel Injection System, Cooling System, Lubrication System, Transmission (Automatic and Manual), Drivetrain, Differentials, Axles, CV Joints Chassis: Suspension (Front and Rear), Steering System, Brake System (Front and Rear, ABS), Wheels and Tires Electrical: Body Control Module (BCM), Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM), Lighting Systems, Power Accessories (Windows, Locks, Mirrors), Audio Systems, HVAC Control, Instrument Cluster, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Fuses and Relays Body: Interior Trim, Exterior Body Panels, Doors, Hood, Liftgate, Bumpers, Glass, Seats, Restraint Systems (Airbags, Seatbelts) Procedures Included Maintenance: Oil Change, Filter Replacement, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspection and Replacement, Brake Pad and Rotor Replacement, Tire Rotation, Air Filter Replacement Diagnostics: Troubleshooting guides, symptom-based diagnostics, DTC interpretation and resolution, component testing Repair: Engine overhaul and rebuild, transmission repair and overhaul, brake caliper and master cylinder replacement, power steering system repair, suspension component replacement, electrical component diagnosis and replacement, body panel repair and replacement Specifications: Torque specifications, fluid capacities, electrical specifications, diagnostic parameters, component tolerances Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for easy navigation and information retrieval Print Quality Quality: High-resolution scans of original factory documentation Scalability: Vector graphics and text allow for clear viewing at any zoom level Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Option 1: 2.4L DOHC 4-Cylinder (GEMA) Engine Option 2: 3.3L OHV V6 (EGA) Engine Option 3: 3.8L OHV V6 (EGA) Engine Option 4: 2.5L Turbo Diesel (VM Motori VM 84C) Engine Option 5: 2.8L Turbo Diesel (VM Motori VM 84C) Performance 3.3L V6 Horsepower: Approx. 158 hp @ 4600 rpm 3.3L V6 Torque: Approx. 190 lb-ft @ 3200 rpm 3.8L V6 Horsepower: Approx. 180 hp @ 4000 rpm 3.8L V6 Torque: Approx. 232 lb-ft @ 3200 rpm Fuel System Gasoline Injection: Multi-Point Fuel Injection (MPI) Diesel Injection: Direct Injection (DI) with Turbocharging Technical Details Bore Stroke 3.3L: 3.94 in x 3.57 in (100.0 mm x 90.5 mm) Bore Stroke 3.8L: 3.92 in x 3.98 in (99.5 mm x 101.0 mm) 🔧 Transmission Standard Standard Transmission: 4-Speed Automatic (41TE/42LE) Optional Optional Transmission: 5-Speed Manual (for 2.4L and Diesel variants in some markets) Features Automatic Features: Electronically Controlled, Lock-up Torque Converter Fluid Specifications Automatic Fluid Type: ATF+4 (Mopar) Fluid Capacities Automatic Capacity Approx: 4.0 - 4.5 quarts (3.8 - 4.3 liters) 📐 Dimensions Exterior Wheelbase: Approx. 112.5 inches (2858 mm) Length: Approx. 189.1 inches (4803 mm) Width: Approx. 72.1 inches (1831 mm) Height: Approx. 68.4 inches (1737 mm) Interior Passenger Volume: Variable by configuration, typically over 150 cubic feet Cargo Cargo Volume Behind 3Rd Row: Approx. 25-30 cubic feet Cargo Volume Max With 2Nd 3Rd Row Removed: Approx. 140-150 cubic feet Weights Curb Weight Approx: 3,700 - 4,200 lbs (1678 - 1905 kg), depending on engine and configuration Gross Vehicle Weight Rating Gvwr Approx: 5,700 - 6,000 lbs (2585 - 2721 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (for 2002 model year) NHTSA Front Impact Passenger: 4 Stars (for 2002 model year) IIHS Front Offset Impact: Acceptable (for 2002 model year) Active Features ABS: Standard on most trims, Anti-lock Braking System Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Driver and front passenger airbags, available side-impact airbags Seatbelts: 3-point seatbelts in all seating positions, front seatbelt pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player, cassette player, and optional premium sound systems. Available rear-seat entertainment systems on higher trims. Driver Assistance Cruise Control: Standard cruise control system. Connectivity Power Accessories: Power windows, power door locks, power mirrors, and power liftgate...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform:

👋 Introduction

Market Position

Segment:

Minivan

Positioning Statement:

The Dodge Caravan was a cornerstone of the minivan segment, offering practicality, versatility, and value for families and businesses. This manual provides the essential technical data needed to maintain and repair these reliable vehicles.

Competitive Analysis

Key Competitors:

Chrysler Town & Country, Plymouth Voyager, Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna

Key Features

Vehicle Appeal:

Spacious interior, flexible seating configurations, family-friendly features, wide range of powertrain options.

Manual Advantage:

Directly sourced from factory data, ensuring accuracy and completeness for all repair and maintenance tasks.

📋 Manual Details

Coverage Areas

Trims Covered:

All trims

Engine Variants Covered:

2.5L Diesel, 2.8L Diesel, 2.4L 4-Cylinder, 3.3L V6, 3.8L V6

Page Count

Estimated Pages:

Over 2000 (typical for a complete factory workshop manual)

Manual Type

Type:

Factory Service Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Ignition System, Exhaust System, Diesel Injection System, Cooling System, Lubrication System, Transmission (Automatic and Manual), Drivetrain, Differentials, Axles, CV Joints

Chassis:

Suspension (Front and Rear), Steering System, Brake System (Front and Rear, ABS), Wheels and Tires

Electrical:

Body Control Module (BCM), Powertrain Control Module (PCM), Engine Control Module (ECM), Transmission Control Module (TCM), Lighting Systems, Power Accessories (Windows, Locks, Mirrors), Audio Systems, HVAC Control, Instrument Cluster, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Fuses and Relays

Body:

Interior Trim, Exterior Body Panels, Doors, Hood, Liftgate, Bumpers, Glass, Seats, Restraint Systems (Airbags, Seatbelts)

Procedures Included

Maintenance:

Oil Change, Filter Replacement, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspection and Replacement, Brake Pad and Rotor Replacement, Tire Rotation, Air Filter Replacement

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, DTC interpretation and resolution, component testing

Repair:

Engine overhaul and rebuild, transmission repair and overhaul, brake caliper and master cylinder replacement, power steering system repair, suspension component replacement, electrical component diagnosis and replacement, body panel repair and replacement

Specifications:

Torque specifications, fluid capacities, electrical specifications, diagnostic parameters, component tolerances

Technical Depth

Depth:

Comprehensive: Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for easy navigation and information retrieval

Print Quality

Quality:

High-resolution scans of original factory documentation

Scalability:

Vector graphics and text allow for clear viewing at any zoom level

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

2.4L DOHC 4-Cylinder (GEMA)

Engine Option 2:

3.3L OHV V6 (EGA)

Engine Option 3:

3.8L OHV V6 (EGA)

Engine Option 4:

2.5L Turbo Diesel (VM Motori VM 84C)

Engine Option 5:

2.8L Turbo Diesel (VM Motori VM 84C)

Performance

3.3L V6 Horsepower:

Approx. 158 hp @ 4600 rpm

3.3L V6 Torque:

Approx. 190 lb-ft @ 3200 rpm

3.8L V6 Horsepower:

Approx. 180 hp @ 4000 rpm

3.8L V6 Torque:

Approx. 232 lb-ft @ 3200 rpm

Fuel System

Gasoline Injection:

Multi-Point Fuel Injection (MPI)

Diesel Injection:

Direct Injection (DI) with Turbocharging

Technical Details

Bore Stroke 3.3L:

3.94 in x 3.57 in (100.0 mm x 90.5 mm)

Bore Stroke 3.8L:

3.92 in x 3.98 in (99.5 mm x 101.0 mm)

🔧 Transmission

Standard

Standard Transmission:

4-Speed Automatic (41TE/42LE)

Optional

Optional Transmission:

5-Speed Manual (for 2.4L and Diesel variants in some markets)

Features

Automatic Features:

Electronically Controlled, Lock-up Torque Converter

Fluid Specifications

Automatic Fluid Type:

ATF+4 (Mopar)

Fluid Capacities

Automatic Capacity Approx:

4.0 - 4.5 quarts (3.8 - 4.3 liters)

📐 Dimensions

Exterior

Wheelbase:

Approx. 112.5 inches (2858 mm)

Length:

Approx. 189.1 inches (4803 mm)

Width:

Approx. 72.1 inches (1831 mm)

Height:

Approx. 68.4 inches (1737 mm)

Interior

Passenger Volume:

Variable by configuration, typically over 150 cubic feet

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 25-30 cubic feet

Cargo Volume Max With 2Nd 3Rd Row Removed:

Approx. 140-150 cubic feet

Weights

Curb Weight Approx:

3,700 - 4,200 lbs (1678 - 1905 kg), depending on engine and configuration

Gross Vehicle Weight Rating Gvwr Approx:

5,700 - 6,000 lbs (2585 - 2721 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (for 2002 model year)

NHTSA Front Impact Passenger:

4 Stars (for 2002 model year)

IIHS Front Offset Impact:

Acceptable (for 2002 model year)

Active Features

Standard on most trims, Anti-lock Braking System

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags:

Driver and front passenger airbags, available side-impact airbags

Seatbelts:

3-point seatbelts in all seating positions, front seatbelt pretensioners

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player, cassette player, and optional premium sound systems. Available rear-seat entertainment systems on higher trims.

Driver Assistance

Cruise Control:

Standard cruise control system.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors, and power liftgate (on some models).

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

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

Oil Change Interval Diesel:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km), depending on usage and fluid type.

Spark Plug Replacement 2.4L:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Spark Plug Replacement V6:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Fluid Specifications

Engine Oil 3.3L/3.8L:

SAE 3.0W-30 Synthetic or Conventional (API Certified)

Engine Oil 2.4L:

SAE 5W-30 Synthetic or Conventional (API Certified)

Engine Coolant:

Mopar Antifreeze/Coolant (HOAT) or equivalent, 50/50 mix with distilled water.

Brake Fluid:

DOT 3

Known Issues

Transmission Problems:

Potential for torque converter shudder, internal component wear, and solenoid issues, particularly in higher mileage vehicles. Regular fluid changes are critical.

Engine Mounts:

Worn engine mounts can lead to excessive vibration and noise.

Suspension Components:

Wear in ball joints, tie rod ends, and bushings can cause steering looseness and premature tire wear.

Power Sliding Doors:

Mechanism wear and electrical issues can affect the operation of power sliding doors.

Heater Core:

Leaking heater cores are a known issue, often requiring dashboard removal for replacement.

📚 Vehicle History

Brand Heritage

Dodge Heritage:

Dodge, a division of Chrysler Corporation, has a long history of producing reliable and versatile vehicles, with a strong presence in the truck and van segments.

Model Evolution

Third Generation Start:

The 2001 model year marked the beginning of the third generation for the Dodge Caravan (and its Chrysler and Plymouth siblings), featuring a significant redesign with improved aerodynamics, interior space, and updated powertrains.

2002 Updates:

Minor refinements and option package adjustments were typical for the 2002 model year, building upon the successful third-generation redesign.

Production

Manufacturing Locations:

Primarily manufactured in North America, including Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

🏆 Awards & Recognition

Recognitions

Common Awards:

While specific awards for the 2002 model year are numerous, the Caravan consistently received accolades for its practicality, value, and family-friendly features from automotive publications and consumer groups throughout its generation.