🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2002

👋 Introduction

Positioning:

The 2002 Dodge Caravan was a highly popular minivan, a segment leader for many years, known for its practicality, seating capacity, and family-oriented features. This manual serves owners and independent repair shops needing accurate, official repair information.

Competition:

Competed directly with the Honda Odyssey, Toyota Sienna, Ford Windstar, and Chevrolet Venture. The Caravan's strength lay in its affordability and wide dealer network.

Vehicle Features:

Flexible seating configurations (Stow 'n Go seating was introduced later, but flexible seating was a hallmark), optional all-wheel drive (though not for the 2002 model in this manual's coverage), comfortable ride, substantial cargo volume.

Manual Benefits:

Official licensing ensures accuracy and completeness. Software format offers quick access, searchability, and portability compared to bulky printed manuals. Crucial for DIY mechanics and independent shops.

📋 Manual Details

Engine:

3.3L V6 (EGA), 3.8L V6 (L32)

Transmission:

4-speed Automatic (41TE, 42LE)

Drivetrain:

Front-Wheel Drive (FWD)

Body Styles:

Short Wheelbase (SWB), Long Wheelbase (LWB)

Estimated Pages:

Approximately 2000+ pages (typical for comprehensive service manuals)

Type:

Service and Repair Manual Software

Language:

English

Format:

Digital Software (likely PDF or proprietary application)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder heads, pistons, crankshaft, camshafts, valve train, timing systems, lubrication, cooling system.

Engine Management:

Fuel injection, ignition system, emissions control, engine diagnostics, OBD-II system.

Transmission Drivetrain:

Automatic transmission overhaul, valve body, torque converter, clutches, bands, planetary gears, differential, axles, CV joints.

Brakes:

Hydraulic system, ABS, brake rotors, pads, calipers, master cylinder, wheel cylinders, parking brake.

Suspension Steering:

Front suspension (struts, control arms, ball joints, tie rods), rear suspension (leaf springs, shocks, control arms), steering rack, power steering system, wheel alignment.

Electrical Electronics:

Battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM), power windows, locks, mirrors.

HVAC:

Air conditioning system (refrigerant, compressor, condenser, evaporator), heating system (heater core, blower motor, controls).

Body Interior:

Exterior body panels, doors, hood, liftgate, interior trim, seats, dashboard, SRS (airbag) system.

Maintenance:

Oil change, filter replacement, fluid checks and changes (coolant, brake fluid, transmission fluid, power steering fluid), spark plug replacement, belt inspection/replacement, air filter replacement.

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, fault code interpretation (OBD-II), circuit testing, pressure testing.

Repair:

Engine component replacement (e.g., water pump, alternator, starter), transmission component replacement, brake component replacement, suspension and steering component replacement, electrical component repair.

Rebuilds:

Engine overhaul, transmission overhaul, component sub-assembly repair.

Specifications:

Torque specifications for fasteners, diagnostic parameter data, fluid capacities, wiring diagrams, component identification.

Depth:

Comprehensive: Covers everything from basic maintenance and fluid changes to in-depth engine and transmission diagnostics and rebuild procedures. Includes detailed troubleshooting guides and wiring schematics.

📊 Manual Specifications

File Format:

Digital Software (likely executable or PDF)

Quality:

High-resolution digital images and text, ensuring clarity for diagrams and procedures.

Binding:

N/A (Software-based)

Paper:

N/A (Software-based)

⚙️ Engine Specifications

Engine 1 Code:

EGA

Engine 1 Displacement:

3.3 Liters (201 cubic inches)

Engine 1 Configuration:

Overhead Valve (OHV) V6

Engine 1 Horsepower:

158 hp @ 4600 rpm

Engine 1 Torque:

190 lb-ft @ 3200 rpm

Engine 2 Code:

L32

Engine 2 Displacement:

3.8 Liters (230 cubic inches)

Engine 2 Configuration:

Overhead Valve (OHV) V6

Engine 2 Horsepower:

180 hp @ 4600 rpm

Engine 2 Torque:

220 lb-ft @ 3200 rpm

Fuel Delivery:

Multi-port Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane recommended)

🔧 Transmission

Transmission Type:

4-Speed Automatic Transaxle

Transmission Code 1:

41TE (for 3.3L engine)

Transmission Code 2:

42LE (for 3.8L engine)

Transmission Features:

Electronic control, overdrive, torque converter lock-up.

📐 Dimensions

Wheelbase Swb:

112.1 inches

Wheelbase Lwb:

119.3 inches

Length Swb:

189.7 inches

Length Lwb:

201.0 inches

Seating Capacity:

Up to 7 passengers

Cargo Volume Swb Behind 2Nd Row:

Approx. 85.1 cu ft

Cargo Volume Lwb Behind 3Rd Row:

Approx. 49.0 cu ft

Curb Weight Est Min:

Approx. 3800 lbs

Gross Vehicle Weight Rating Est Min:

Approx. 5000 lbs

🛡️ Safety Features

NHTSA Driver Front Impact:

4 Stars (for 2002 model)

NHTSA Passenger Front Impact:

4 Stars (for 2002 model)

ABS:

Standard on most trims (Anti-lock Braking System)

Traction Control:

Optional on some trims

Airbags:

Driver and front passenger airbags, optional side airbags (less common).

Seat Belts:

Three-point seat belts for all seating positions, front seat belt pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM/CD or cassette player, with optional premium sound systems and rear entertainment (DVD player was not common in 2002 but possible on high trims).

Cruise Control:

Standard on most trims.

Rear Parking Aid:

Optional on some higher trim levels.

Auxiliary Inputs:

Not standard; typically requires aftermarket modification.

🔧 Maintenance

Oil Change Interval:

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

Transmission Fluid Change:

Every 30,000-60,000 miles (depending on severity of use and fluid type). Crucial for longevity of the 41TE/42LE transmission.

Coolant Change:

Initially at 60,000 miles or 5 years, then every 30,000 miles or 3 years thereafter (Chrysler's HOAT coolant is often specified).

Spark Plug Replacement:

Typically at 100,000 miles for original equipment platinum or iridium plugs.

Engine Oil:

SAE 5W-30 (API Certified, meets Chrysler MS-6395 specification).

Transmission Fluid:

ATF+4 (Automatic Transmission Fluid +4), Chrysler MS-9602.

Coolant:

Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), typically a 50/50 mix with distilled water. Meets Chrysler MS-9769.

Power Steering Fluid:

ATF+4 or Mopar Power Steering Fluid.

Transmission Problems:

The 41TE/42LE automatic transmissions are prone to solenoid failures, torque converter clutch issues, and valve body wear, especially if fluid maintenance is neglected. Shuddering, delayed engagement, or harsh shifts are common symptoms.

Engine Mounts:

Worn engine mounts can lead to excessive vibration and noise, particularly at idle or during acceleration.

Front Suspension:

Ball joints, tie rod ends, and control arm bushings can wear prematurely, leading to steering looseness and uneven tire wear.

Radiator Leaks:

Plastic end tanks on the radiator can degrade and leak coolant over time.

📚 Vehicle History

Dodge Heritage:

Dodge, a division of Chrysler Corporation (later DaimlerChrysler), has a long history in American automotive manufacturing, known for trucks, muscle cars, and eventually minivans.

Caravan Generation:

The 2002 model is part of the third generation of the Dodge Caravan (1996-2000), which was redesigned for the 2001 model year, marking the start of the fourth generation. This generation introduced a more rounded styling and updated powertrains.

Production Locations:

Primarily manufactured in North America, notably at the Windsor Assembly Plant in Ontario, Canada.

🏆 Awards & Recognition

Segment Performance:

The Dodge Caravan was consistently a top seller in the minivan segment for many years, indicating strong market acceptance and consumer demand for its practicality and value.