🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2002

Generation:

Third Generation (NS)

Platform Code:

NS

👋 Introduction

Market Position:

Essential resource for 2002 Dodge Caravan owners and independent repair shops seeking accurate, factory-level repair and maintenance information.

Competitive Analysis:

Offers superior detail and factory accuracy compared to generic aftermarket repair manuals. Provides dealership-level diagnostic procedures and specifications.

Key Features:

Actual factory manual content, detailed illustrations and photos, comprehensive diagnostic trees, printable on demand, lifetime accessibility.

Value Proposition:

Enables DIY repairs and maintenance, potentially saving hundreds or thousands of dollars in labor costs compared to dealership or independent shop rates.

📋 Manual Details

Coverage Areas:

Comprehensive service, diagnosis, and repair

Page Count:

Estimated 2000+ pages (typical for factory service manuals of this era)

Manual Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Digital (CD-ROM originally, now downloadable PDF)

📖 Manual Coverage

Systems Covered:

Lubrication & Maintenance, Suspension, Differential & Driveline, Brakes, Cooling System, Battery, Starting Systems, Charging System, Ignition System, Instrument Panel Systems, Audio Systems, Horn Systems, Vehicle Speed Control System, Turn Signal & Hazard Warning Systems, Wipers & Washer Systems, Lamps, Passive Restraint Systems, Electrically Heated Systems, Power Lock Systems, Power Window Systems, Power Mirror Systems, Chime/Buzzer Warning Systems, Overhead Console Systems, Wiring Diagrams, Engine, Exhaust System, Frame & Bumpers, Fuel System, Steering, Transmission & Transfer Case, Tires & Wheels, Body, Heating & Air Conditioning, Emission Control System

Procedures Included:

Detailed step-by-step repair procedures, diagnostic troubleshooting charts, exploded views, torque specifications, component removal and installation, routine maintenance, adjustments, specifications, wiring diagrams

Technical Depth:

In-depth, covering everything from basic fluid checks and filter changes to complex engine and transmission diagnostics and rebuilds, including electrical system troubleshooting and body component repair.

Wiring Diagrams:

Detailed, system-specific wiring diagrams for all electrical components and circuits, crucial for troubleshooting electrical faults.

Troubleshooting:

Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for mechanical and electrical systems.

Body Repair:

Includes procedures for body panels, bumpers, doors, windows, and interior trim components.

Diagnostics:

Covers OBD-II (On-Board Diagnostics II) system, fault codes (DTCs), and diagnostic procedures for engine and powertrain control modules.

Torque Specifications:

Precise torque values for all critical fasteners across various systems (engine, suspension, brakes, etc.).

📊 Manual Specifications

File Format:

PDF (.pdf)

Print Quality:

High-resolution, designed for clear printing of text, photos, diagrams, and wiring schematics.

Binding Type:

N/A (Digital format, printable)

Paper Type:

N/A (Digital format, user-dependent upon printing)

Searchability:

PDF format allows for keyword searching of specific terms, procedures, or parts.

⚙️ Engine Specifications

Primary Engine:

3.3L V6 OHV (EGA/EGE)

Optional Engine:

3.8L V6 OHV (L32)

Horsepower 3.3L:

150 hp @ 4700 rpm

Torque 3.3L:

185 lb-ft @ 3300 rpm

Horsepower 3.8L:

180 hp @ 4500 rpm

Torque 3.8L:

230 lb-ft @ 3200 rpm

Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Ignition System:

Distributorless Ignition System (DIS) with individual ignition coils

Emission Control:

Catalytic Converter, Oxygen Sensors (O2S), Exhaust Gas Recirculation (EGR)

🔧 Transmission

Standard Transmission:

4-speed automatic (41TE)

Optional Transmission:

None specified for 2002 model year

Transmission Fluid Spec:

ATF+4 (Mopar Material Number 05013457GA or equivalent)

Transmission Capacity:

Approx. 9.5 quarts (9.0 L) for refill, 12.8 quarts (12.1 L) for overhaul

📐 Dimensions

Exterior Length:

189.4 inches (4810 mm)

Exterior Width:

72.0 inches (1829 mm)

Exterior Height:

68.9 inches (1750 mm)

Wheelbase:

112.1 inches (2847 mm)

Curb Weight Approx:

4,000 - 4,300 lbs (1814 - 1950 kg) depending on configuration

Cargo Volume:

Approx. 143.7 cu ft (4069 L) with rear seats removed

🛡️ Safety Features

Ratings NHTSA:

N/A (NHTSA ratings were less detailed/standardized in 2002 for minivans)

Active Features:

Anti-lock Braking System (ABS), Traction Control (optional on some trims)

Passive Features:

Driver and front passenger airbags, optional side airbags, front seatbelt pretensioners, child seat anchor points (LATCH)

Brake System:

Front: Ventilated discs; Rear: Drums (standard), Rear: Disc (optional/higher trims)

Tire Size Standard:

P215/65R16

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

💡 Technology Features

Infotainment:

Factory AM/FM/CD or cassette player, optional premium audio systems, rear seat entertainment options (rare for 2002).

Driver Assistance:

Cruise control (standard on most models).

Connectivity:

N/A (No factory integrated Bluetooth or USB connectivity in 2002 models)

Instrument Panel:

Analog gauges (speedometer, tachometer, fuel, coolant temp), warning lights, trip odometer, outside temperature display (optional).

🔧 Maintenance

Service Intervals Oil Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (with synthetic blend or synthetic oil).

Service Intervals Air Filter:

Replace every 30,000 miles (48,000 km) or as needed based on inspection.

Service Intervals Spark Plugs:

Replace at 100,000 miles (160,000 km) with Iridium spark plugs (refer to manual for exact type and gap).

Fluid Specifications Engine Oil:

SAE 5W-30 (API Certified, meeting Chrysler MS-6395)

Fluid Specifications Coolant:

Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), 50/50 mixture with distilled water

Fluid Specifications Brake Fluid:

DOT 3 brake fluid

Fluid Specifications Power Steering Fluid:

Mopar Power Steering Fluid (or equivalent, typically Dexron III compatible)

Known Issues 2002 Caravan:

Common issues can include radiator leaks, EGR valve clogging, power window motor failures, front suspension wear (ball joints, tie rods), and intermittent electrical problems. The manual will provide detailed diagnostic and repair procedures for these.

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 L) with filter for 3.3L, 5.0 quarts (4.7 L) with filter for 3.8L

Coolant Capacity:

Approx. 11.5 quarts (10.9 L) for 3.3L, 12.0 quarts (11.4 L) for 3.8L

📚 Vehicle History

Brand Heritage:

Dodge, a division of Chrysler Corporation (later DaimlerChrysler), has a long history of producing popular family vehicles.

Model Evolution:

The 2002 Caravan is part of the third generation (NS) of the Dodge Caravan, introduced for the 1996 model year. This generation saw significant redesigns and updates, including improved safety and powertrain options.

Production Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)

Production Years Generation:

1996-2000 (NS platform for original design), 2001-2007 (PG platform for updated design - this manual likely covers the updated PG platform for 2002)

🏆 Awards & Recognition

Recognitions:

The Dodge Caravan was a consistently popular vehicle, often appearing on 'best seller' lists for minivans during its era due to its practicality and value.

Ratings:

Consumer satisfaction and reliability ratings vary by year and specific issues, but the platform was generally well-received for its utility. The manual will help address and resolve common wear-and-tear items.