🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Model Variant:

Grand Caravan

Year:

2002

Chassis Code:

NS (for this generation of minivan)

👋 Introduction

Segment:

Mid-size minivan segment, a highly competitive market for family transportation.

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza.

Vehicle Attributes:

Spacious interior, versatile seating configurations, comfortable ride, available all-wheel drive (on some trims), family-oriented features.

Target Audience:

Professional technicians, experienced DIY mechanics, fleet maintenance personnel.

📋 Manual Details

Regions Covered:

USA, Europe

Estimated Page Count:

Varies by specific manual, but typically 1000+ pages for comprehensive service and diagnostic manuals.

Type:

Service Manual, Diagnostic Manuals (Gasoline & Diesel)

Language:

English

Format:

Likely digital (PDF), potentially printable sections.

📖 Manual Coverage

Engine Systems:

Engine mechanical, lubrication, cooling, fuel delivery (including injection), ignition, emissions control, timing, performance tuning, diagnostics.

Transmission Systems:

Automatic transmission (e.g., 42LE, 41TE), manual transmission (if applicable), clutch, transfer case (if applicable), driveline, torque converter, diagnostics and repair.

Brakes Systems:

Hydraulic systems, ABS, EBD, parking brake, brake pad and rotor replacement, caliper service, bleeding procedures, diagnostics.

Electrical Systems:

Battery, charging system, starting system, lighting, instrumentation, power accessories (windows, locks, mirrors), HVAC controls, body control module (BCM), wiring diagrams, component testing.

Suspension Steering:

Front suspension (MacPherson struts), rear suspension (independent or solid axle depending on configuration), steering gear, power steering, wheel alignment, diagnostics.

Body Chassis:

Body structure, doors, hinges, latches, glass, interior trim, exterior trim, body repair, rust prevention, underbody coatings.

HVAC Systems:

Air conditioning (refrigerant circuits, compressor, condenser, evaporator), heating systems, climate control, blower motor, diagnostics.

Diagnostic Systems:

On-Board Diagnostics (OBD-II) procedures, diagnostic trouble codes (DTCs), scan tool usage, component testing, troubleshooting charts, flowcharts.

Maintenance Procedures:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid level checks and top-offs, belt inspections and replacement, battery maintenance.

Repair Procedures:

Engine component replacement (alternator, starter, water pump), brake caliper and rotor replacement, suspension component replacement (shocks, struts, ball joints), exhaust system repair, door and latch repair.

Diagnostic Procedures:

Troubleshooting drivability issues, electrical system faults, HVAC problems, transmission shifting concerns, using diagnostic tools and equipment.

Rebuild Procedures:

Engine disassembly, inspection, and reassembly; transmission overhaul and component replacement; detailed torque specifications for critical fasteners.

Wheel Tire Service:

Tire pressure checks, rotation, replacement, wheel balancing, alignment specifications, lug nut torque specifications.

Lighting Service:

Headlight bulb replacement, taillight assembly replacement, interior light bulb replacement, fuse identification and replacement.

Diagnostic Codes:

Detailed listing and interpretation of OBD-II diagnostic trouble codes (DTCs) relevant to the 2002 Dodge Caravan and Grand Caravan.

Depth:

Comprehensive, covering everything from basic preventative maintenance to in-depth diagnostic troubleshooting and component-level repair.

Diagnostic Focus:

Strong emphasis on systematic diagnosis, including flowcharts, symptom-based troubleshooting, and component testing procedures, particularly for gasoline and diesel powertrains.

📊 Manual Specifications

File Format:

Digital (likely PDF). Searchable text and bookmark functionality are typical for professional manuals.

Print Quality:

High resolution, allowing for clear reproduction of diagrams, schematics, and text. Suitable for printing key sections.

Binding Type:

N/A (for digital format, but if printed, typically comb-bound or spiral-bound for lay-flat use in a workshop).

Paper Type:

N/A (for digital format, but professional print manuals often use heavy-duty, coated paper to withstand workshop conditions).

⚙️ Engine Specifications

Engine Options:

2.4L (2378cc) DOHC I4 (GEMA), 3.3L (3301cc) OHV V6 (EGA), 3.8L (3778cc) OHV V6 (EVE).

2 4L I4 Horsepower:

Approx. 150 hp @ 5200 rpm

2 4L I4 Torque:

Approx. 160 lb-ft @ 4000 rpm

3 3L V6 Horsepower:

Approx. 180 hp @ 5000 rpm

3 3L V6 Torque:

Approx. 205 lb-ft @ 3600 rpm

3 8L V6 Horsepower:

Approx. 200 hp @ 5000 rpm

3 8L V6 Torque:

Approx. 240 lb-ft @ 3200 rpm

Fuel Delivery:

Multi-port Fuel Injection (MPI) for gasoline engines. Diesel information available in separate diagnostic manual.

Fuel Type:

Unleaded gasoline (87 octane recommended for all engines, but check owner's manual for specific recommendations).

Emissions Control:

Catalytic converter, oxygen sensors, EGR system, evaporative emission control (EVAP) system.

🔧 Transmission

Transmission Type:

All engines typically paired with a 4-speed automatic transmission (e.g., 41TE/42LE variants).

Optional Transmission:

Manual transmission was not commonly offered on Grand Caravan models of this era, primarily automatic.

Automatic Transmission Features:

Electronically controlled, torque converter lock-up, overdrive gear.

Transmission Fluid Type:

ATF+4 (Mopar Automatic Transmission Fluid) or equivalent is typically specified for Chrysler automatic transmissions of this era. Always verify with the specific manual.

📐 Dimensions

Wheelbase:

Approx. 119.3 inches (Grand Caravan)

Length:

Approx. 199.0 inches (Grand Caravan)

Width:

Approx. 71.9 inches

Height:

Approx. 67.5 inches

Cargo Volume Behind First Row:

Approx. 140.5 cu ft (with second and third rows folded/removed)

Cargo Volume Behind Second Row:

Approx. 83.2 cu ft

Curb Weight:

Varies by engine and trim, typically between 4,100 - 4,500 lbs.

Towing Capacity:

Up to 3,800 lbs with optional towing package.

🛡️ Safety Features

NHTSA Front Crash Test:

Generally received good ratings, often 4 or 5 stars for driver and passenger protection in frontal impacts for this generation.

IIHS Front Crash Test:

Good ratings in frontal offset tests by IIHS.

Anti Lock Brakes:

Standard on Grand Caravan models.

Traction Control:

Available on some models, particularly those with V6 engines or AWD.

Electronic Stability Control:

Not widely available or standard on 2002 models; became more common in later years.

Airbags:

Frontal airbags for driver and passenger; available side-impact airbags for front and/or second-row occupants.

Seat Belts:

Three-point seat belts for all seating positions, integrated child seat anchors (LATCH).

💡 Technology Features

Audio System:

Base AM/FM stereo with CD player or cassette tape. Optional premium Infinity speaker systems, rear entertainment systems (DVD player) available on higher trims.

Climate Control:

Manual HVAC controls standard; optional automatic climate control available on higher trims.

Cruise Control:

Standard on most models.

Parking Assist:

Rear parking assist sensors were an available option on some models.

Auxiliary Input:

Not typically available in this era; later models might have had aftermarket adapter options.

🔧 Maintenance

Oil Change Interval:

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

Transmission Fluid Change:

Recommended every 30,000-60,000 miles, depending on use and fluid condition. Critical for longevity.

Spark Plug Replacement:

Varies by plug type; platinum or iridium plugs can last 100,000 miles, while conventional plugs require more frequent replacement (e.g., 30,000-60,000 miles).

Engine Oil Type:

API certified SAE 5W-30 or 10W-30 viscosity, depending on ambient temperature. Check manual for exact spec.

Coolant Type:

Mopar Antifreeze/Coolant (ethylene glycol based, typically orange/pink for Chrysler vehicles of this era) or equivalent. A 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Type:

ATF+4 or specific power steering fluid recommended by Chrysler. Consult manual.

Common Problems:

Transmission solenoid pack failures (especially 41TE/42LE), rear suspension sag/spring breakage, HVAC blower motor resistor failure, oil leaks from valve cover gaskets, power door lock actuators failing, cooling system leaks (radiator, hoses), starter motor issues.

Preventative Measures:

Regular transmission fluid and filter changes, checking coolant levels and condition, inspecting suspension components periodically, keeping battery terminals clean.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the Caravan in 1984, establishing a dominant position.

Generation:

This 2002 model belongs to the second generation of the Dodge Caravan (platform shared with Chrysler Voyager/Town & Country), which ran from 1996 to 2000, and an extended second generation (often referred to as 2.5 generation) from 2001 to 2007.

Manufacturing Plants:

Windsor Assembly Plant, Ontario, Canada and St. Louis Assembly Plant, Missouri, USA.

🏆 Awards & Recognition

Family Vehicle Awards:

The Dodge Caravan and Grand Caravan consistently ranked well in family vehicle surveys and received awards from automotive publications for practicality and value in their segment throughout their production runs.

Consumer Reports Reliability:

Reliability ratings varied by model year and powertrain. Early 2000s models sometimes had mixed reviews, particularly regarding transmission longevity.