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Dodge Caravan 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Codes Platform: NS (Second Generation) 👋 Introduction Market Position Positioning: A highly popular and practical minivan known for its spacious...
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Dodge Caravan 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2002
Codes
Platform:
NS (Second Generation)
👋 Introduction
Market Position
Positioning:
A highly popular and practical minivan known for its spacious interior, versatility, and family-friendly features. Positioned as a reliable and affordable option in the minivan segment.
Competitive Analysis
Competitors:
Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture
Key Features
Features:
Flexible seating arrangements (Stow 'n Go later models, but still versatile in 2002), comfortable ride, ample cargo space, availability of all-wheel-drive (later models, not typical for 2002), user-friendly controls.
📋 Manual Details
Coverage Areas
Engine Variants Covered:
2.4L I4, 3.3L V6, 3.8L V6
Transmission Variants Covered:
4-speed Automatic (32LE, 41TE, 42LE)
Trim Levels Covered:
All trim levels (e.g., SE, Sport, ES)
Page Count
Estimated Pages:
Approximately 1000+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Transmission (Automatic)
Chassis:
Suspension (Front & Rear), Steering System, Brake System (ABS Included), Wheels & Tires
Electrical:
Body Electrical System, Lighting, Instruments, HVAC System, Audio System, Powertrain Control Module (PCM), Antilock Brake System (ABS) Module
Body:
Exterior Body Panels, Interior Trim, Doors, Windows, Seats, Convertible Top (if applicable)
Procedures Included
Maintenance:
Oil Change, Filter Replacement, Fluid Checks & Replacements, Spark Plug Replacement, Belt Inspection & Replacement
Repair:
Engine Overhaul, Transmission Rebuild, Brake Pad & Rotor Replacement, Suspension Component Replacement, Electrical Component Diagnosis & Replacement
Diagnostics:
OBD-II Diagnosis, Symptom-Based Troubleshooting, Component Testing (e.g., sensors, actuators)
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission overhauls, including detailed wiring diagrams and diagnostic procedures)
📊 Manual Specifications
File Format
Quality:
High-Resolution, Searchable Text, Printable Pages
Print Quality
Quality:
Clear, Legible Text and Diagrams
Binding Type
Type:
N/A (Digital PDF)
Paper Type
Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.4L (2429cc) DOHC Inline-4 (GEMA)
Engine 2:
3.3L (3301cc) OHV V6 (EGA)
Engine 3:
3.8L (3778cc) OHV V6 (EGH)
Performance
2.4L Horsepower:
150 hp @ 5600 rpm
2.4L Torque:
165 lb-ft @ 4000 rpm
3.3L Horsepower:
180 hp @ 5000 rpm
3.3L Torque:
205 lb-ft @ 3600 rpm
3.8L Horsepower:
190 hp @ 4700 rpm
3.8L Torque:
232 lb-ft @ 3200 rpm
Fuel System
System:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic
Optional
Transmission Type:
N/A (Standard across models)
Features
Transmission Codes:
32LE (2.4L), 41TE (3.3L/3.8L FWD), 42LE (3.3L/3.8L AWD - AWD not common for 2002 model year)
Fluid Type:
ATF+4 (Mopar)
📐 Dimensions
Exterior
Wheelbase:
113.0 inches
Length:
188.5 inches
Width:
72.0 inches
Height:
67.5 inches
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.6 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 75.6 cu ft
Cargo Volume Max:
Approx. 140.0 cu ft
Weights
Curb Weight Min:
Approx. 3,800 lbs
Curb Weight Max:
Approx. 4,200 lbs
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
★★★★☆ (4 stars)
NHTSA Passenger Front Impact:
★★★★☆ (4 stars)
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Optional (TCS)
Passive Features
Airbags Front:
Standard Driver and Passenger Airbags
Airbags Side:
Optional (Front Side Airbags)
Seatbelts:
All positions with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Base AM/FM stereo, optional CD player, optional premium Infinity sound system.
Rear Seat Entertainment:
Optional rear-seat video system (less common on 2002 models compared to later years).
Driver Assistance
Cruise Control:
Standard
Parking Sensors:
Optional (Rear ParkSense)
Connectivity
Connectivity Options:
Limited to basic audio input; no USB or Bluetooth connectivity in this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult manual for specifics)
Engine Air Filter:
Inspect every 15,000 miles, replace as needed
Cabin Air Filter:
Replace annually or every 12,000-15,000 miles (if equipped)
Spark Plugs:
3.3L/3.8L V6: 100,000 miles (Platinum; check manual for specific type). 2.4L I4: 60,000-100,000 miles (consult manual).
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on driving conditions (consult manual for ATF+4)
Fluid Specifications
Engine Oil:
SAE 5W-30 (API Certified, check manual for exact specification)
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (50/50 mix)
Brake Fluid:
DOT 3
Known Issues
Common Problem 1:
Transmission issues: Torque converter shudder, slipping, or failure (especially in earlier NS models, but still possible). Regular fluid changes are crucial.
Common Problem 2:
Water pump leaks: Common on V6 engines, often requiring replacement. Coolant leaks from hoses or radiator are also prevalent.
Common Problem 3:
Front suspension components: Ball joints, tie rod ends, and control arm bushings can wear out, leading to clunking noises and alignment issues.
Common Problem 4:
Power steering pump leaks: Can develop leaks, leading to noise and loss of assist.
Common Problem 5:
Rear liftgate latch/handle issues: Can become stiff or break due to wear and weather exposure.
📚 Vehicle History
Brand Heritage
Dodge Heritage:
Founded in 1900, Dodge Brothers Company initially supplied components to Ford. It evolved into a full-fledged automobile manufacturer, known for robust and performance-oriented vehicles. Later, it became part of Chrysler Corporation.
Model Evolution
Caravan Generations:
The 2002 Dodge Caravan belongs to the second generation (NS, 1996-2000) and subsequent facelifted models (RS, 2001-2007). This era saw significant updates in styling, interior features, and powertrain options.
Production
Manufacturing Location:
Windsor, Ontario, Canada and St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Award 1:
Often recognized for its value and practicality in automotive reviews of its era.
Ratings
Kbb Rating:
Consistently ranked well for its affordability and utility in the used car market.
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