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DODGE CARAVAN 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Codes Vehicle Code: RS 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, commercial use Competitive Analysis Key Competitors...
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DODGE CARAVAN 2002 Full Service Repair ManualDODGE CARAVAN 2002 Full Service Repair ManualDODGE CARAVAN 2002 Full Service Repair ManualDODGE CARAVAN 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2002
Codes
Vehicle Code:
RS
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, commercial use
Competitive Analysis
Key Competitors 2002:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Vehicle Selling Points:
Spacious interior, flexible seating, family-friendly features, good cargo capacity.
📋 Manual Details
Coverage Areas
Documentation Type:
Full Service & Repair Manual
Page Count
Estimated Pages:
1500+
Manual Type
Manual Type:
Professional Technician's Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, but format not explicitly stated, assuming digital for sale)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed diagnosis, repair, overhaul for all engine variants.
Engine Electrical:
Ignition system, fuel injection, sensors, control modules (PCM), wiring diagrams.
Transmission Automatic:
Diagnosis, repair, overhaul, fluid specifications, torque converter.
Transmission Manual:
Diagnosis, repair, overhaul, fluid specifications (if applicable).
Brakes:
Hydraulic system, ABS, disc/drum components, parking brake, bleeding procedures.
Steering:
Power steering system, rack and pinion, steering column, alignment.
Suspension:
Front/rear suspension components, struts, shocks, springs, bushings, wheel bearings.
HVAC:
Air conditioning, heating, ventilation, blower motor, climate control module.
Electrical Chassis:
Lighting, wipers, power windows/locks, mirrors, horn, interior/exterior lighting.
Body And Frame:
Body panel removal/installation, interior trim, door mechanisms, glass replacement.
Exhaust System:
Muffler, catalytic converter, pipes, hangers, heat shields.
Fuel System:
Fuel pump, injectors, lines, tank, evaporative emissions system (EVAP).
Procedures Included
Preventative Maintenance:
Oil changes, filter replacements, fluid checks, belt inspection, spark plug replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common fault finding.
Engine Repair:
Engine rebuild, cylinder head service, piston/ring replacement, gasket replacement.
Transmission Repair:
Transmission overhaul, solenoid replacement, valve body service, clutch adjustment (if manual).
Brake Service:
Brake pad/shoe replacement, rotor resurfacing/replacement, brake caliper service, bleeding.
Suspension Repair:
Strut/shock replacement, ball joint replacement, tie rod end replacement, bushing replacement.
Electrical Diagnostics:
Using multimeters, oscilloscope, scan tools, tracing wiring faults.
HVAC Repair:
Refrigerant handling, leak detection, component replacement (compressor, evaporator, heater core).
Body Work:
Door handle replacement, window regulator repair, mirror replacement, panel alignment.
Technical Depth
Diagnostic Capabilities:
Includes diagnostic trouble codes (DTCs), sensor data interpretation, component testing.
Repair Procedures:
Detailed step-by-step instructions with torque specifications and special tool requirements.
Component Overhaul:
Covers complete disassembly, inspection, and reassembly of major components.
Wiring Diagrams:
Comprehensive, component-level wiring schematics for all electrical systems.
📊 Manual Specifications
File Format
Digital Format Details:
Likely searchable PDF, optimized for viewing and printing key sections.
Print Quality
Print Quality Suitability:
High resolution images and diagrams suitable for printing.
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
EGA (2.4L Inline-4), ESX (3.3L V6), EGJ (3.8L V6)
Displacement Inline 4:
2.4 Liters
Displacement V6 Small:
3.3 Liters
Displacement V6 Large:
3.8 Liters
Performance
Horsepower 2.4L:
150 hp @ 5600 rpm (approx.)
Torque 2.4L:
170 lb-ft @ 4400 rpm (approx.)
Horsepower 3.3L:
180 hp @ 5000 rpm (approx.)
Torque 3.3L:
205 lb-ft @ 3600 rpm (approx.)
Horsepower 3.8L:
200 hp @ 5000 rpm (approx.)
Torque 3.8L:
235 lb-ft @ 3200 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-Port Fuel Injection (MPFI)
Fuel Type:
Unleaded gasoline
Ignition System:
Distributorless Ignition System (DIS) or Distributor-based (depending on engine)
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic
Optional
Transmission Type Optional:
5-speed Manual (rarely equipped on Caravan, more common on Plymouth Voyager/Chrysler Voyager)
Features
Transmission Control:
Electronically controlled automatic transmission
📐 Dimensions
Exterior
Length:
177.5 - 200.2 inches (depending on wheelbase)
Width:
72.0 inches
Height:
68.4 inches
Wheelbase:
112.1 inches (standard), 119.2 inches (long)
Interior
Passenger Capacity:
7
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20-30 cu. ft. (depending on wheelbase)
Cargo Volume Behind 2Nd Row:
Approx. 70-80 cu. ft. (depending on wheelbase)
Cargo Volume Behind 1St Row:
Approx. 140-150 cu. ft. (depending on wheelbase)
Weights
Curb Weight:
3,700 - 4,200 lbs (approx.)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
4 Stars (2002 model year estimate)
NHTSA Passenger Front Impact:
4 Stars (2002 model year estimate)
Active Features
ABS:
Standard on most models, optional on base trims.
Traction Control:
Available on some V6 models.
Passive Features
Airbags Front:
Driver and passenger front airbags standard.
Airbags Side:
Optional front side airbags available.
Seatbelts:
3-point seatbelts for all seating positions.
💡 Technology Features
Infotainment
Audio System:
AM/FM radio, CD player, cassette player (optional).
Display:
Basic digital or analog radio display.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Connectivity Options:
Limited; no integrated Bluetooth or USB ports for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (using synthetic blend or full synthetic oil).
Transmission Fluid Change:
Every 60,000 - 100,000 miles (refer to manual for specific recommendations and fluid type).
Spark Plug Replacement:
Every 100,000 miles for platinum or iridium plugs (check engine variant).
Fluid Specifications
Engine Oil Spec:
API SN/SN PLUS or newer, SAE 5W-30 (check owner's manual for specific viscosity recommendations based on climate).
Transmission Fluid Spec:
ATF+4 (Mopar Genuine or equivalent).
Coolant Spec:
Mopar OAT (Orange) Antifreeze/Coolant, or equivalent HOAT (Hybrid Organic Acid Technology) coolant.
Known Issues
Common Electrical Problems:
Window regulator failures, power lock actuator issues, intermittent dashboard warning lights due to module faults.
Common Engine Problems:
Oil leaks from valve cover gaskets, intake manifold gasket leaks (especially on V6 engines), some ignition coil failures.
Common Transmission Problems:
Slipping in gears, delayed engagement, or harsh shifting can indicate worn clutches or valve body issues.
Common Suspension Problems:
Worn strut mounts, ball joints, and tie rod ends can lead to knocking noises and alignment issues.
Common HVAC Problems:
Blend door actuator failures, AC compressor leaks, or clogged cabin air filters.
📚 Vehicle History
Brand Heritage
Dodge Brand Focus:
Known for performance and value, often targeting a younger demographic or offering more utility.
Model Evolution
Caravan Generation:
Second Generation (1996-2000) leading into the Third Generation facelift (2001-2007).
Platform:
Chrysler's AS platform (shared with Plymouth Voyager and Chrysler Voyager).
Production
Manufacturing Location:
Windsor, Ontario, Canada; Saint Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Vehicle Awards Context:
The Dodge Caravan and its platform siblings were consistently recognized for their practicality and value as family vehicles during this era.
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