🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2002

Platform Code:

NS (Second Generation)

Chrysler Internal Code:

Not specified, but the NS platform was a continuation and enhancement of previous Caravan platforms.

👋 Introduction

Segment:

Mid-size minivan, a segment dominated by vehicles like the Honda Odyssey, Toyota Sienna, and Ford Windstar. The Caravan was a strong contender known for its practicality and affordability.

Key Competitors:

Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Oldsmobile Silhouette, Toyota Sienna, Honda Odyssey.

Value Proposition:

Offered flexible seating configurations, a comfortable ride, and a range of powertrain options, including the efficient 2.4L four-cylinder and the robust 3.3L and 3.8L V6 engines. The 2.5L Turbo Diesel was a niche offering for those prioritizing fuel economy or towing.

Model Significance:

The 2002 model year falls within the second generation (NS) of the Dodge Caravan, representing a refinement of the platform introduced in 1996. It continued to be a benchmark in minivan design and functionality.

📋 Manual Details

Primary Coverage:

Comprehensive repair and maintenance for the 2002 Dodge Caravan.

Secondary Coverage:

Includes troubleshooting, diagnostics, and technical specifications.

Estimated Page Count:

Likely over 1000 pages, typical for a full factory service manual.

Type:

Factory Service Repair Manual (FSM)

Language:

English

File Format:

PDF

Download Type:

Instant Download

📖 Manual Coverage

Powertrain:

Engine (including 2.5L Turbo Diesel variant), Transmission, Differential & Driveline, Exhaust System, Fuel System, Cooling System, Turbocharger Systems.

Chassis:

Suspension, Brakes, Steering, Tires/Wheels, Frame & Bumpers.

Body:

Body construction, doors, windows, interior trim, heating and air conditioning (HVAC), lighting, wipers/washers.

Electrical:

Audio system, chime/buzzer systems, electronic control modules (ECMs/PCMs), engine control, instrument cluster, lamps, message systems, power systems, speed control, vehicle theft security, wiring diagrams.

Emissions:

Emissions control systems (including specific details for the 2.5L Turbo Diesel).

Maintenance:

Scheduled maintenance, lubrication, fluid changes, filter replacements, component checks.

Repair:

Step-by-step diagnostic and repair procedures for all major systems, including engine overhaul, transmission service, brake component replacement, suspension repair, electrical troubleshooting, and bodywork.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, and common issue resolutions.

Specifications:

Torque specifications, fluid capacities and types, component clearances, electrical resistance values, and diagnostic parameter readings.

Depth:

Comprehensive. Covers basic maintenance through to complex mechanical and electrical repairs, including detailed wiring diagrams and diagnostic procedures.

📊 Manual Specifications

Searchability:

Likely text-searchable if the PDF was created from scanned OCR or native digital files, enabling quick keyword searches for specific procedures or components.

Printability:

Yes, indicated as printable. Quality will depend on the source PDF's resolution and clarity.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

Reader Software:

Adobe PDF Reader

Operating Systems:

Windows and Mac compatible

⚙️ Engine Specifications

Engine 1:

2.4L DOHC 16-valve I4 (GEMA)

Engine 1 Horsepower:

150 hp @ 5600 rpm

Engine 1 Torque:

170 lb-ft @ 4000 rpm

Engine 2:

3.3L OHV 12-valve V6 (EGA)

Engine 2 Horsepower:

158 hp @ 4500 rpm

Engine 2 Torque:

199 lb-ft @ 3200 rpm

Engine 3:

3.8L OHV 12-valve V6 (L32)

Engine 3 Horsepower:

180 hp @ 4200 rpm

Engine 3 Torque:

235 lb-ft @ 3200 rpm

Engine 4 Diesel:

2.5L Turbo Diesel I4 (VM Motori)

Engine 4 Diesel Horsepower:

Approx. 114 hp (Varies by specific tuning)

Engine 4 Diesel Torque:

Approx. 175 lb-ft (Varies by specific tuning)

Fuel Delivery:

Multi-port Fuel Injection (MPI) for gasoline engines; Direct injection and turbocharging for diesel.

Cooling Type:

Liquid-cooled, pressurized system with thermostatically controlled fan.

🔧 Transmission

Transmission 1:

42LE 4-Speed Automatic Transmission (Standard on most V6 models)

Transmission 2:

41TE 4-Speed Automatic Transmission (Often paired with the 2.4L and 3.3L engines)

Transmission Diesel:

Typically paired with a manual transmission or a specific automatic for diesel applications, though the 42LE was also common.

Overdrive:

All automatic transmissions featured overdrive for improved fuel economy.

Transmission Fluid:

ATF+4 (Mopar Automatic Transmission Fluid) or equivalent is typically recommended. Consult manual for exact specification by transmission model.

📐 Dimensions

Wheelbase:

112.2 inches

Length:

189.4 inches (short wheelbase); 202.2 inches (long wheelbase - Grand Caravan)

Width:

72.0 inches

Height:

67.5 inches

Seating Capacity:

7 or 8 passengers, depending on configuration.

Cargo Volume Behind 3Rd Row:

Approx. 30-40 cubic feet (varies by wheelbase)

Cargo Volume Max:

Approx. 140-160 cubic feet (with rear seats removed)

Curb Weight:

Approx. 3,600 - 4,200 lbs (varies by engine and trim)

Towing Capacity:

Up to 3,800 lbs (with proper towing package and V6 engine)

🛡️ Safety Features

NHTSA Front Crash Test Driver:

4/5 Stars (as per typical results for this generation)

NHTSA Front Crash Test Passenger:

4/5 Stars (as per typical results for this generation)

IIHS Side Impact Rating:

Good (for models equipped with side airbags, if available for 2002)

ABS:

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

Optional Traction Control System (TCS) on some models.

Airbags Front:

Driver and front passenger airbags standard.

Airbags Side:

Optional side-impact airbags available on select trims.

Seat Belts:

Three-point seat belts for all seating positions.

💡 Technology Features

Audio Systems:

Available AM/FM/CD players, with optional cassette tape players and premium Infinity speaker systems. Sirius satellite radio was also becoming available.

Display Screens:

No integrated navigation or advanced touchscreen displays; basic digital or analog readouts for climate control and audio.

Cruise Control:

Standard cruise control on most trims.

Parking Sensors:

Optional rear parking assist sensors were available on higher trims.

Usb Bluetooth:

No factory USB or Bluetooth connectivity; aftermarket solutions would be required.

🔧 Maintenance

Oil Change:

Every 3,000-5,000 miles or 3-6 months for conventional oil; 5,000-7,500 miles or 6 months for synthetic oil (refer to manual for exact recommendations based on engine and driving conditions).

Transmission Fluid Change:

Every 30,000-60,000 miles, depending on transmission type and usage. Crucial for the longevity of the 4-speed automatics.

Coolant Change:

Every 30,000-60,000 miles or 2-4 years, using appropriate Mopar coolant.

Spark Plugs:

Platinum or Iridium plugs (depending on engine) typically have intervals of 60,000-100,000 miles.

Engine Oil:

SAE 5W-30 is common for V6 engines, while 5W-30 or 10W-30 may be used for the 2.4L and 2.5L Diesel. Always confirm with the manual.

Coolant:

Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically orange or pink. Do not mix with other types.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Transmission Problems:

The 42LE and 41TE transmissions, while generally robust, can experience issues like torque converter shudder, slipping, or failure to engage gears, especially with high mileage and neglected fluid changes. Accumulator bores can wear.

Engine Mounts:

Engine mounts, particularly the rear mount, are known to deteriorate, leading to vibrations and clunking noises.

Window Regulators:

Power window regulators can fail, causing windows to become inoperable or fall into the door.

Cooling Fan Motors:

Cooling fan motors can fail, leading to overheating, especially in traffic.

Cv Joints:

Front CV joints are wear items and can fail, producing clicking noises during turns.

📚 Vehicle History

Dodge Legacy:

Dodge, as part of Chrysler Corporation (later DaimlerChrysler), has a long history of innovation in the automotive sector, particularly with the minivan segment it helped pioneer.

Generation:

Second Generation (NS), produced from 1996 to 2000. The 2001 model year marked the beginning of the third generation (RS), which carried significant styling and mechanical updates. This manual covers the final year of the second generation, which received minor updates over its run.

Manufacturing Locations:

Primarily Windsor, Ontario, Canada (Windsor Assembly Plant), and Saltillo, Mexico (Saltillo South Engine Plant for some components).

Model Years:

2002

🏆 Awards & Recognition

Car And Driver 10Best:

While not specifically for 2002, the Caravan and its siblings were frequent mentions or recipients of '10Best' lists from automotive publications in prior years for redefining the minivan segment.

Consumer Reports:

Consumer Reports ratings for this generation varied; while praised for utility and space, reliability perceptions could be mixed depending on the specific powertrain and year.