2002 Dodge Caravan Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Body Style: Minivan Generation Generation Name: Third Generation (RS) Codes Platform Code: NS (shared with Plymouth Voyager, Chrysler Town & Country) 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals needing versatile cargo and passenger capacity. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza, Mercury Villager, Nissan Quest. Key Features Vehicle Strengths: Spacious interior, flexible seating arrangements, good cargo capacity, availability of all-wheel drive (AWD) on some configurations, relatively robust powertrains for the era. Manual Value Proposition: Provides factory-level diagnostic and repair information, empowering owners and independent shops to perform complex repairs and maintenance, saving significant dealership costs. 📋 Manual Details Coverage Areas Manual Title: 2002 Dodge Caravan Service Repair Manual Primary Coverage Focus: Repair, Maintenance, Rebuild Trim Level Coverage: All US and Canadian trim levels (e.g., SE, ES) Page Count Estimated Page Count: 1500-2000+ (typical for comprehensive factory manuals) Manual Type Manual Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system (belts/chains), lubrication system, cooling system, intake and exhaust manifolds, fuel injection system, ignition system. Transmission Drivetrain: Automatic Transmission (e.g., 41TE, 42LE), manual transmission (less common), torque converter, transmission fluid service, clutches, gears, seals, differential, axle shafts, CV joints. Brakes: Front disc brakes, rear drum or disc brakes, ABS system, hydraulic lines, master cylinder, power booster, parking brake, brake fluid specifications and bleeding procedures. Suspension Steering: Front independent suspension (McPherson struts), rear torsion beam or solid axle, shocks, springs, control arms, ball joints, tie rod ends, power steering system, steering column, rack and pinion. Electrical Electronics: Battery, charging system (alternator), starting system (starter), fuses, relays, wiring diagrams, lighting system (headlights, taillights, interior), instrument cluster, body control module (BCM), power windows, power locks, power seats, mirrors, HVAC blower motor, horn, diagnostic trouble codes (DTCs). HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, blower motor, climate control unit, HVAC system diagnosis and repair. Body Interior: Body panels, doors, hood, liftgate, bumpers, glass, interior trim, seats, seat belts, airbags, instrument panel, dashboard, carpeting, sound deadening. Restraint Systems: Front airbags, side airbags (if equipped), seat belt pre-tensioners, SRS system diagnosis and component replacement. Emission Controls: Catalytic converter, O2 sensors, EGR system, evaporative emission control (EVAP) system, PCM (Powertrain Control Module) emissions strategies. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, spark plug replacement, air filter replacement, cabin air filter replacement. Troubleshooting Diagnostics: Step-by-step diagnostic charts for common drivability issues, electrical faults, HVAC problems, brake concerns, and other malfunctions. Includes diagnostic trouble code (DTC) interpretation and diagnostic flowcharts. Repair Rebuild: Detailed procedures for component removal, installation, adjustment, and rebuilding. Covers engine rebuilds, transmission overhauls, brake caliper replacement, suspension component replacement, etc. Component Replacement: Specific instructions for replacing major components like alternators, starters, fuel pumps, water pumps, radiators, AC compressors, window regulators, door handles, etc. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, grounds, sensor circuits, actuator circuits, and control modules. Torque Specifications: Precise torque values for all critical fasteners, including engine components, suspension parts, brake assemblies, and wheel lug nuts. Technical Depth Depth Level: Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced electrical diagnostics and body repair. Diagnostic Tools: Mentions use of scan tools (e.g., DRB III for Chrysler/Dodge vehicles) for retrieving DTCs and accessing live data. Special Tools: Identifies and illustrates specific special tools required for certain repair procedures. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely searchable text (OCR optimized for digital manuals). Print Quality Image Resolution: High resolution for clear diagrams, illustrations, and photographs. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 3.3L (201.5 cu in) V6 OHV Engine Code: EGA Bore X Stroke: 3.44 x 3.62 inches (87.4 x 91.9 mm) Compression Ratio: 9.3:1 Horsepower Hp: 180 hp @ 5000 rpm (approx.) Torque Lb-Ft: 205 lb-ft @ 3200 rpm (approx.) Valve Train: Overhead Valve (OHV), 2 valves per cylinder Engine Options Optional Engine Type: 3.8L (231.5 cu in) V6 OHV (less common for '02 Caravan, more prevalent in earlier years/other Chrysler minivans) Fuel System Fuel Delivery: Multi-port Electronic Fuel Injection (MPI) Fuel Type: 87 Octane Unleaded Gasoline Fuel Pump Type: In-tank Electric Engine Oil Recommended Oil Viscosity: SAE 5W-30 Oil Capacity Quarts: 4.5 (with filter change) Cooling System Coolant Type: HOAT (Hybrid Organic Acid Technology) - typically Mopar Antifreeze/Coolant 10 Year/100,000 Mile Formula Coolant Capacity Quarts: 12.0 (approx.) 🔧 Transmission Standard Transmission Type: 4-speed Automatic (41TE) Optional Optional Transmission Type: All-Wheel Drive (AWD) available...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Body Style:

Minivan

Generation

Generation Name:

Third Generation (RS)

Codes

Platform Code:

NS (shared with Plymouth Voyager, Chrysler Town & Country)

👋 Introduction

Market Position

Vehicle Segment:

Minivan

Target Audience:

Families, individuals needing versatile cargo and passenger capacity.

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza, Mercury Villager, Nissan Quest.

Key Features

Vehicle Strengths:

Spacious interior, flexible seating arrangements, good cargo capacity, availability of all-wheel drive (AWD) on some configurations, relatively robust powertrains for the era.

Manual Value Proposition:

Provides factory-level diagnostic and repair information, empowering owners and independent shops to perform complex repairs and maintenance, saving significant dealership costs.

📋 Manual Details

Coverage Areas

Manual Title:

2002 Dodge Caravan Service Repair Manual

Primary Coverage Focus:

Repair, Maintenance, Rebuild

Trim Level Coverage:

All US and Canadian trim levels (e.g., SE, ES)

Page Count

Estimated Page Count:

1500-2000+ (typical for comprehensive factory manuals)

Manual Type

Manual Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital File (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system (belts/chains), lubrication system, cooling system, intake and exhaust manifolds, fuel injection system, ignition system.

Transmission Drivetrain:

Automatic Transmission (e.g., 41TE, 42LE), manual transmission (less common), torque converter, transmission fluid service, clutches, gears, seals, differential, axle shafts, CV joints.

Brakes:

Front disc brakes, rear drum or disc brakes, ABS system, hydraulic lines, master cylinder, power booster, parking brake, brake fluid specifications and bleeding procedures.

Suspension Steering:

Front independent suspension (McPherson struts), rear torsion beam or solid axle, shocks, springs, control arms, ball joints, tie rod ends, power steering system, steering column, rack and pinion.

Electrical Electronics:

Battery, charging system (alternator), starting system (starter), fuses, relays, wiring diagrams, lighting system (headlights, taillights, interior), instrument cluster, body control module (BCM), power windows, power locks, power seats, mirrors, HVAC blower motor, horn, diagnostic trouble codes (DTCs).

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, blower motor, climate control unit, HVAC system diagnosis and repair.

Body Interior:

Body panels, doors, hood, liftgate, bumpers, glass, interior trim, seats, seat belts, airbags, instrument panel, dashboard, carpeting, sound deadening.

Restraint Systems:

Front airbags, side airbags (if equipped), seat belt pre-tensioners, SRS system diagnosis and component replacement.

Emission Controls:

Catalytic converter, O2 sensors, EGR system, evaporative emission control (EVAP) system, PCM (Powertrain Control Module) emissions strategies.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, spark plug replacement, air filter replacement, cabin air filter replacement.

Troubleshooting Diagnostics:

Step-by-step diagnostic charts for common drivability issues, electrical faults, HVAC problems, brake concerns, and other malfunctions. Includes diagnostic trouble code (DTC) interpretation and diagnostic flowcharts.

Repair Rebuild:

Detailed procedures for component removal, installation, adjustment, and rebuilding. Covers engine rebuilds, transmission overhauls, brake caliper replacement, suspension component replacement, etc.

Component Replacement:

Specific instructions for replacing major components like alternators, starters, fuel pumps, water pumps, radiators, AC compressors, window regulators, door handles, etc.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, grounds, sensor circuits, actuator circuits, and control modules.

Torque Specifications:

Precise torque values for all critical fasteners, including engine components, suspension parts, brake assemblies, and wheel lug nuts.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced electrical diagnostics and body repair.

Diagnostic Tools:

Mentions use of scan tools (e.g., DRB III for Chrysler/Dodge vehicles) for retrieving DTCs and accessing live data.

Special Tools:

Identifies and illustrates specific special tools required for certain repair procedures.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely searchable text (OCR optimized for digital manuals).

Print Quality

Image Resolution:

High resolution for clear diagrams, illustrations, and photographs.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

3.3L (201.5 cu in) V6 OHV

Engine Code:

Bore X Stroke:

3.44 x 3.62 inches (87.4 x 91.9 mm)

Compression Ratio:

9.3:1

Horsepower Hp:

180 hp @ 5000 rpm (approx.)

Torque Lb-Ft:

205 lb-ft @ 3200 rpm (approx.)

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder

Engine Options

Optional Engine Type:

3.8L (231.5 cu in) V6 OHV (less common for '02 Caravan, more prevalent in earlier years/other Chrysler minivans)

Fuel System

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Fuel Type:

87 Octane Unleaded Gasoline

Fuel Pump Type:

In-tank Electric

Engine Oil

Recommended Oil Viscosity:

SAE 5W-30

Oil Capacity Quarts:

4.5 (with filter change)

Cooling System

Coolant Type:

HOAT (Hybrid Organic Acid Technology) - typically Mopar Antifreeze/Coolant 10 Year/100,000 Mile Formula

Coolant Capacity Quarts:

12.0 (approx.)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic (41TE)

Optional

Optional Transmission Type:

All-Wheel Drive (AWD) available with 4-speed Automatic (42LE)

Features

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid)

Transmission Fluid Capacity Quarts:

4.0 (approx. dry fill)

📐 Dimensions

Exterior

Wheelbase Inches:

119.3

Length Inches:

193.5

Width Inches:

Height Inches:

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inch)

Lug Nut Torque Ft-Lbs:

100-130

Cargo

Cargo Volume Behind 3Rd Row Cu Ft:

27.9 (approx.)

Cargo Volume Behind 2Nd Row Cu Ft:

76.0 (approx.)

Cargo Volume Behind 1St Row Cu Ft:

140.0 (approx.)

Weights

Curb Weight Lbs:

4000-4500 (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

Four-star driver, four-star passenger (for the 2002 model year as per NHTSA)

IIHS Small Overlap Front Crash Rating:

N/A (Test not performed on vehicles of this era)

Active Features

Standard on most models, optional on some.

Traction Control:

Optional on some models.

Passive Features

Airbags:

Standard front driver and passenger airbags. Optional side airbags.

Seat Belts:

3-point seat belts with pretensioners for all outboard seating positions. Integrated child seats often available.

💡 Technology Features

Infotainment

Audio System Options:

Standard AM/FM stereo with cassette and CD player. Optional premium audio systems with more speakers and amplifier.

Rear Seat Entertainment:

Optional rear-seat video screens and VCR/DVD players were available on higher trim levels.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Assist:

Rear parking sensors were an option on some models.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors, power sliding doors (optional on some models).

Remote Keyless Entry:

Available on most models.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles:

7,500 miles or 6 months (synthetic oil recommended), 3,000 miles or 3 months (conventional oil)

Air Filter Replacement Miles:

15,000-30,000 miles

Cabin Air Filter Replacement Miles:

15,000-30,000 miles

Spark Plug Replacement Miles:

100,000 miles (Platinum or Iridium plugs)

Transmission Fluid Service Miles:

60,000-100,000 miles (depending on driving conditions and fluid type)

Coolant Flush Miles:

100,000 miles or 5 years

Serpentine Belt Inspection Miles:

60,000-100,000 miles (replacement as needed)

Fluid Specifications

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 or specific Mopar power steering fluid

Known Issues

Common Problems:

Transmission solenoid issues (slipping, harsh shifts), EGR valve clogging, coolant leaks (especially from gaskets), rear axle bearing wear, power window regulator failures, interior trim rattles, ABS sensor failures.

Engine Idle Instability:

Often related to vacuum leaks, dirty throttle body, or faulty Idle Air Control (IAC) valve.

📚 Vehicle History

Brand Heritage

Dodge Brand Focus:

Known for performance and practicality, with the Caravan being a cornerstone of their family vehicle offerings.

Model Evolution

Third Generation Introduction:

The third generation (RS) began in 1996 and was a significant redesign from the original K-car based Caravan. It featured a more aerodynamic shape and improved packaging. The 2002 model year represents a refinement of this platform.

Facelift Timing:

The RS generation received a refresh for the 2001 model year, introducing updated styling, interior features, and powertrain enhancements, making the 2002 model part of this refreshed iteration.

Production

Assembly Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA.

🏆 Awards & Recognition

Recognitions

Car And Driver Best 20:

Car and Driver's 10 Best Trucks list, often including minivans, depending on the year and specific review criteria. While not always specifically awarded, the Caravan platform was highly regarded in its segment during its production run.

Ratings

Consumer Satisfaction:

Varies by model year and specific configuration. Generally considered competitive for its class at the time, but some powertrain and reliability concerns were noted by consumer organizations.

Certifications

Manual Accuracy Certification:

This is a factory-produced manual, reflecting Chrysler's engineering and service standards.