🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2002

Product Type:

Service and Repair Manual

Platform:

NS (Facelift)

👋 Introduction

Segment:

Minivan (Mid-size)

Key Selling Points Vehicle:

Versatile interior, family-friendly features, value for money, Stow 'n Go seating precursor.

Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager.

Manual Advantage:

Vehicle-specific, technician-level detail ensures accuracy and completeness, vital for proper maintenance and repair of a complex vehicle like the Caravan.

Manual Target Audience:

Professional mechanics, DIY enthusiasts, fleet maintenance personnel.

📋 Manual Details

General Coverage:

All Models, All Repairs A-Z

Technical Level:

Technician Level (Dealership Equivalent)

Estimated Pages:

1500-2000 (typical for comprehensive service manuals of this era)

Type:

Factory Service Manual (FSM)

Language:

English

Format:

Printed (typical for original FSMs), PDF (common for digital sales)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, cylinder heads, crankshaft, pistons, connecting rods, camshafts, timing systems, oil pump, lubrication.

Engine Performance:

Fuel system, ignition system, emission controls, cooling system, intake manifold, exhaust system, engine diagnostics and tuning.

Transmission:

Automatic transmission (e.g., 41TE, 42LE) service, disassembly, assembly, hydraulic control, torque converter, electronic controls, diagnostics.

Drivetrain:

Front-wheel drive axle shafts, CV joints, differential, transfer case (if applicable), propeller shaft (if applicable).

Suspension:

Front suspension (struts, control arms, ball joints, steering knuckles), rear suspension (solid axle, leaf springs/coil springs, shock absorbers), alignment specifications.

Brakes:

Front disc brakes, rear drum brakes (common), ABS system components, hydraulic lines, brake fluid specifications, bleeding procedures, parking brake.

Steering:

Power steering system, steering gear/rack and pinion, steering column, tie rod ends, alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system, fuses, relays, wiring diagrams.

Body And Interior:

Body panel removal/installation, doors, hood, tailgate, interior trim, seating, HVAC system (heating, ventilation, air conditioning), door locks, power windows, mirrors.

Body Electrical:

Instrument cluster, body control module (BCM), power accessories, security systems, interior/exterior lighting, wiper system.

Diagnostics:

Comprehensive diagnostic procedures for powertrain control module (PCM), anti-lock braking system (ABS), and body control module (BCM).

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, spark plug replacement, belt replacement.

Repair:

Component replacement (alternator, starter, water pump, radiator, master cylinder, suspension components, interior/exterior parts), minor engine and transmission repairs.

Troubleshooting:

Diagnostic flowcharts for common and complex issues, symptom-based troubleshooting guides.

Specifications:

Torque specifications for all fasteners, fluid capacities, engine timing, suspension alignment angles, electrical specifications.

Wiring Diagrams:

Detailed, vehicle-specific wiring schematics for all major systems.

Wheel Alignment:

Front and rear alignment specifications and procedures.

Fuel System Diagnosis:

Fuel pump testing, injector diagnosis, fuel pressure testing.

Hvvac Service:

Refrigerant handling (R-134a), component replacement (compressor, condenser, evaporator), blower motor, blend door actuators, heater core replacement.

Body Repair:

Door panel removal, tailgate latch repair, bumper cover replacement, glass replacement procedures.

Depth:

Comprehensive: Covers routine maintenance, component replacement, advanced diagnostics, and some major overhaul procedures. Suitable for DIY enthusiasts and professional technicians.

📊 Manual Specifications

Digital Format:

PDF (Searchable, Bookmarked chapters for ease of navigation)

Print Quality:

High Resolution (Clear text, legible diagrams and illustrations)

Binding:

Perfect Bound (for printed versions, durable and lay-flat design)

Paper Type:

Durable, semi-gloss paper (for printed versions, resistant to workshop grease and dirt)

⚙️ Engine Specifications

Engine Options:

2.4L I4 (DOHC, 16V, 'EDZ'), 3.3L V6 (OHV, 12V, 'EGA'), 3.8L V6 (OHV, 12V, 'EGH')

2.4L I4 Horsepower:

150 hp @ 5200 rpm

2.4L I4 Torque:

170 lb-ft @ 4000 rpm

3.3L V6 Horsepower:

180 hp @ 4800 rpm

3.3L V6 Torque:

205 lb-ft @ 4000 rpm

3.8L V6 Horsepower:

197 hp @ 5600 rpm

3.8L V6 Torque:

235 lb-ft @ 3200 rpm

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

2.4L Code:

EDZ

3.3L Code:

EGA

3.8L Code:

EGH

🔧 Transmission

Transmission Type:

4-speed Automatic Transaxle

Manual Transmission Availability:

Not available for 2002 models in North America.

Common Automatic Transmission:

41TE (for 2.4L and 3.3L), 42LE (for 3.8L)

Transmission Fluid Type:

ATF+4 (Chrysler Mopar)

📐 Dimensions

Wheelbase:

112.1 inches

Length:

189.4 inches

Width:

72.5 inches

Height:

68.4 inches

Curb Weight Range:

3750-4100 lbs (approximate, depending on engine and trim)

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (for 2002)

NHTSA Front Impact Passenger:

4 Stars (for 2002)

NHTSA Side Impact Front Passenger:

4 Stars (for 2002)

ABS:

Standard on all models

Airbags:

Driver and front passenger airbags

Seatbelts:

3-point seat belts for all seating positions

💡 Technology Features

Audio Systems:

AM/FM stereo, CD player (optional), cassette player (optional), premium sound systems available on higher trims.

Cruise Control:

Standard or optional depending on trim level.

Power Accessories:

Power windows, power door locks, power mirrors available on most models.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type (refer to manual for exact recommendations).

Transmission Fluid Change Interval:

Every 30,000-60,000 miles (refer to manual for severe vs. normal driving).

Spark Plug Replacement:

Approx. 60,000-100,000 miles (depending on plug type - platinum/iridium recommended).

Engine Oil Type 2.4L:

SAE 5W-30 (API Service SG or higher)

Engine Oil Type V6:

SAE 5W-30 (API Service SG or higher)

Coolant Type:

Chrysler HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant (OAT or HOAT compatible)

Brake Fluid Type:

DOT 3

Common Problems:

Transmission solenoid issues, power steering leaks, rear axle bearing wear, heater core leaks, ignition coil failure, exhaust manifold cracks (especially on V6 engines).

📚 Vehicle History

Dodge Minivan Legacy:

Dodge is credited with inventing the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984.

Generation Details:

The 2002 model is part of the third generation (2001-2007) of the Dodge Caravan, which saw a significant redesign with improved aerodynamics, styling, and available features. This generation introduced features that would become standard in minivans.

Manufacturing Location:

Windsor, Ontario, Canada; Saltillo, Coahuila, Mexico.

🏆 Awards & Recognition

Car And Driver Editors Choice:

Often cited for its practicality and value by automotive publications in its segment.