🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2002

Platform:

Chrysler NS (minivan)

Chassis Code:

NS (for the generation)

👋 Introduction

Segment:

Mid-size minivan, popular family vehicle.

Key Competitors:

Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Trans Sport.

Versatility:

Known for flexible seating configurations and cargo capacity.

Value Proposition:

Often positioned as a cost-effective option in the minivan segment.

📋 Manual Details

Main Systems Covered:

Engine (including 2.5L Turbo Diesel), Transmission, Brakes, Suspension, Steering, Fuel System, Exhaust System, Cooling System, Electrical Systems, Climate Control, Body, Driveline, Restraints

Estimated Page Count:

High (precise count not provided, but implies extensive detail)

Type:

Service Repair Manual

Language:

English

File Format:

PDF

Compatibility:

WINDOWS and MAC

Software Requirement:

Adobe PDF Reader

Source Type:

Not a scanned manual (implying original digital source or high-quality reproduction)

📖 Manual Coverage

Engine Systems:

Detailed procedures for gasoline and 2.5L Turbo Diesel variants, including fuel injection, ignition control, emissions control, engine mechanicals (disassembly/assembly), cooling, and lubrication.

Transmission And Driveline:

Coverage for automatic transmissions, differential, and driveline components. Specifics on repair and maintenance.

Braking System:

Comprehensive coverage of brake system components, hydraulic systems, and ABS (if equipped).

Suspension And Steering:

Detailed maintenance and repair procedures for front and rear suspension, steering components, and alignment specifications.

Electrical And Electronic Systems:

Extensive coverage of wiring diagrams, electronic control modules (ECM), audio systems, instrument cluster, lighting, horns, power systems, restraints (airbags), message systems, speed control, and vehicle theft security.

Comfort And Convenience:

Includes procedures for heating, air conditioning, wipers, and washers.

Emissions Control:

Detailed coverage of emissions control systems, including catalytic converter, oxygen sensors, EVAP system, and specifications for both gasoline and the 2.5L turbo diesel variants.

Tires And Wheels:

Information on tire sizing, inflation pressures, wheel specifications, and likely wheel bearing maintenance.

Frame And Bumpers:

Procedures for frame inspection, repair, and bumper removal/installation.

Body And Frame:

Covers body panels, doors, windows, bumpers, frame, and exhaust system.

Maintenance Procedures:

Scheduled maintenance, lubrication, fluid changes, filter replacements, and general upkeep.

Repair Procedures:

Step-by-step instructions for component disassembly, repair, and reassembly.

Diagnostic Procedures:

Troubleshooting guides and diagnostic strategies for various systems.

Clutch System:

While primarily automatic, if any manual transmission variants existed for this year/engine, clutch system coverage would be included. The manual lists 'Clutch', so it's likely covered for completeness or specific components.

Installation Procedures:

Implied through detailed repair procedures, such as accessory installations or component replacements.

Depth:

Comprehensive, from basic maintenance to complete disassembly and rebuild of major components. Suitable for both DIY and professional mechanics.

Wiring Diagrams:

Comprehensive wiring diagrams are a critical component of service manuals and are explicitly listed as covered.

Illustrations:

Hundreds of photos and illustrations to guide through procedures.

📊 Manual Specifications

Format:

PDF

Printability:

Yes

Binding:

Digital (PDF), printable

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Engine Option 1:

2.4L Inline-4 (DOHC, 16-valve) - Possibly G4CS/EDZ

Engine Option 2:

3.3L V6 (OHV, 12-valve) - Likely EGA

Engine Option 3:

2.5L Turbo Diesel Inline-4

Horsepower 2 4L:

Approx. 150 hp

Torque 2 4L:

Approx. 165 lb-ft

Horsepower 3 3L V6:

Approx. 180 hp

Torque 3 3L V6:

Approx. 200 lb-ft

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Delivery Diesel:

Turbocharged Direct Injection (DI) or indirect injection system common for diesels of this era.

Cooling Type:

Liquid-cooled

🔧 Transmission

Transmission Type Gasoline:

4-speed Automatic

Transmission Type Diesel:

Likely a 4-speed Automatic, specific model may vary.

Transmission Control:

Electronically controlled automatic transmission.

📐 Dimensions

Wheelbase:

Approx. 112.1 inches

Length:

Approx. 189.5 inches

Cargo Volume Behind 3Rd Row:

Varies by configuration, typically around 20-30 cubic feet.

Cargo Volume Max:

Can exceed 150 cubic feet with rear seats removed/folded.

Curb Weight:

Approx. 3,700 - 4,200 lbs depending on engine and configuration.

🛡️ Safety Features

NHTSA Rollover Rating:

Typically 4 out of 5 stars for minivans of this era, but specific 2002 Caravan ratings should be verified.

ABS:

Available ABS (Anti-lock Braking System).

Airbags:

Standard front airbags for driver and passenger. Side airbags may have been optional.

Seatbelts:

All seating positions equipped with 3-point seatbelts.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player or cassette, optional premium audio systems available. Manual covers diagnostics and repair.

Cruise Control:

Standard or optional speed control system, covered in the manual.

Vehicle Theft Security:

Factory immobilizer system and security alarm. Manual provides diagnostic and repair information.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles depending on oil type (conventional vs. synthetic) and driving conditions. Consult manual for specific recommendations.

Air Filter Replacement:

Recommended every 15,000-30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Varies by spark plug type (e.g., platinum, iridium), typically 30,000-100,000 miles.

Engine Oil Type:

Refer to manual for specific viscosity (e.g., 5W-30 for gasoline engines, diesel specification for 2.5L TD). Likely API SL service category for gasoline.

Coolant Type:

Chrysler's HOAT (Hybrid Organic Acid Technology) or IAT (Inorganic Acid Technology) coolant depending on original fill. Typically Mopar OAT (Orange) or a compatible equivalent.

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid, Type 9602) is the likely specification for Chrysler automatics of this era.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Common Problems:

Transmission issues (especially earlier models), coolant leaks (intake manifold, radiator), power window regulators, fuel pump failures, occasional electrical gremlins.

Diesel Specific Issues:

Glow plug issues, injector pump problems, turbocharger wear, and potential for head gasket issues on high-mileage units.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan/Voyager in the mid-1980s.

Generation:

This 2002 model belongs to the third generation (1996-2007) of the Dodge Caravan, often referred to as the NS platform.

Updates For 2002:

While the core platform remained, minor styling tweaks, interior enhancements, and powertrain refinements were common in this generation's later years.

Manufacturer:

Chrysler Corporation (later DaimlerChrysler).

Manufacturing Location:

Primarily Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

🏆 Awards & Recognition

Past Accolades:

The Caravan model line has historically received various accolades for practicality and value, though specific awards for the 2002 model year would need specific research. Often featured on 'best family vehicle' lists.