Positioning:
The Chrysler Caravan was a segment-defining minivan, offering practicality and family-oriented features. This manual caters to owners and technicians needing detailed factory-level repair and maintenance information.
Competitors:
Directly competes with models like the Dodge Grand Caravan, Plymouth Grand Voyager, Ford Windstar, and Chevrolet Venture of the same era.
Manual Value Proposition:
Provides official Chrysler procedures, diagrams, and specifications, ensuring accuracy and completeness for DIY repairs and professional servicing.
Primary Coverage:
North American Market
Engine Variants Covered:
All gasoline engine options for 2002 Chrysler Caravan
Transmission Variants Covered:
Automatic Transmission models
Estimated Page Count:
Over 1500 pages (typical for comprehensive factory service manuals)
Type:
Factory Service Manual (FSM) / Repair Manual
Format:
Digital (PDF likely), potentially Print
Powertrain:
Engine (mechanical, lubrication, cooling, fuel, ignition, exhaust), Transmission (automatic)
Chassis:
Suspension, Steering, Brakes (ABS, standard), Wheels, Tires
Body:
Body & Frame, Exterior (doors, panels, glass), Interior (trim, seats, HVAC, restraints)
Electrical:
Wiring Diagrams, Lighting, Instrumentation, Power Accessories, Audio System, Powertrain Control Module (PCM), Body Control Module (BCM), Antitheft System
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their interpretation
Repair:
Component removal, disassembly, inspection, repair, assembly, and installation procedures for all major systems
Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical specifications
Depth:
Comprehensive: From basic fluid services to complete engine and transmission overhauls, complex electrical diagnostics, and body panel repairs.
Digital Format:
PDF (Searchable text, bookmarked chapters, high-resolution diagrams)
Print Quality:
High-resolution schematics and diagrams, clear text for readability.
Binding:
N/A (for digital), Stapled/Spiral Bound (for print)
Paper Type:
N/A (for digital), Glossy/Durable paper stock (for print)
Engine Options 2002:
3.3L (3301cc) OHV V6, 3.8L (3778cc) OHV V6
3.3L V6 Horsepower:
150 hp @ 4,500 rpm (approx.)
3.3L V6 Torque:
180 lb-ft @ 3,200 rpm (approx.)
3.8L V6 Horsepower:
165-180 hp @ 4,500 rpm (approx.)
3.8L V6 Torque:
207-225 lb-ft @ 3,000 rpm (approx.)
Fuel Delivery:
Multi-Port Fuel Injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline
PCM Type:
Chrysler's proprietary engine control module (e.g., NGC - Next Generation Controller)
NHTSA Driver Front Impact Rating:
4 Stars (for the 2002 model year, as per common ratings for this generation)
NHTSA Passenger Front Impact Rating:
4 Stars (for the 2002 model year)
ABS:
Standard Anti-lock Braking System (ABS) on front wheels, optional on rear
Traction Control:
Optional Traction Control System (TCS)
Airbags:
Driver and front passenger airbags
Seat Belts:
3-point seat belts in all seating positions, with pretensioners for front seats
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, depending on driving conditions (refer to manual for exact recommendations).
Transmission Fluid Change Interval:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), or as recommended by severe service schedule. Crucial for longevity.
Spark Plug Replacement:
Typically around 100,000 miles (160,000 km) for platinum or iridium plugs (check specific plug type).
Engine Oil Type:
SAE 5W-30 (API Certified, meeting MS-6395)
Engine Oil Capacity:
Approx. 4.5 quarts (4.2 liters) with filter for 3.3L V6; Approx. 4.5 quarts (4.2 liters) with filter for 3.8L V6.
Coolant Type:
Chrysler OAT (Orange) Extended Life Antifreeze/Coolant (MS-9769) - NOT a Dex-Cool equivalent.
Power Steering Fluid:
Chrysler Power Steering Fluid (MS-5943) or equivalent
Common Wear Items:
EGR valve clogging, front suspension components (ball joints, tie rods), wheel bearings, power steering pump leaks, intermittent electrical issues (e.g., door locks, power windows).
Transmission Concerns:
Torque converter shudder, potential for overheating if not properly maintained; ATF+4 fluid is critical.
Engine Specific Issues:
3.8L V8 intake manifold gasket leaks can occur.
Oil Filter Part Number Example:
Wix 51500, Fram PH3550 (Verify specific vehicle application)
Air Filter Part Number Example:
Wix 49018, Fram CA8502 (Verify specific vehicle application)
Chrysler Minivan Legacy:
Chrysler is credited with inventing the minivan segment in the mid-1980s with the original Dodge Caravan/Plymouth Voyager. The Caravan nameplate continued this legacy of family transport.
Ns Generation Introduction:
The NS generation (1996-2000) and its update, the RS (2001-2007), represented significant advancements over earlier models in terms of styling, features, and refinement.
Assembly Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA (for this generation)
Production Years For 2002 Model:
Typically August 2001 to July 2002
Segment Leadership:
Chrysler minivans consistently ranked high in family vehicle awards and sales volumes during this period due to their practicality and innovation.
Consumer Reports History:
While specific ratings vary by year and configuration, the Caravan was generally considered a functional and popular choice for families.
