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 Segment: Minivan Target Audience: Families, commercial users, DIY mechanics Competitive Analysis...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform:

NS (Second Generation)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, commercial users, DIY mechanics

Competitive Analysis

Competitors 2002:

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

Key Features Vehicle

Defining Characteristics:

Versatile interior with Stow 'n Go seating (introduced later in this generation), comfortable ride, ample cargo space, practical for families

Manual Value Proposition

Benefit To Owner:

Empowers owners to perform maintenance and repairs, saving money and ensuring longevity of the vehicle

📋 Manual Details

Coverage Areas

Covered Regions:

North America

Trim Levels Covered:

All available trims (e.g., SE, ES, Sport)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, lubrication, cooling, fuel, ignition, emissions, starting, charging, engine control module (ECM) diagnosis

Transmission Systems:

Automatic transmission (41TE/42LE), manual transmission (NV1500), clutch, driveline, differentials

Chassis Systems:

Suspension (front and rear), steering, brakes (front disc, rear drum/disc, ABS), wheels, tires

Electrical Systems:

Wiring diagrams, lighting, instruments, audio system, power accessories (windows, locks, mirrors), climate control, body control module (BCM), trailer wiring

Body Systems:

Body panels, doors, windows, seats, interior trim, HVAC system, exterior trim, bumpers, glass, sunroof

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad/rotor service, tire rotation

Repair Procedures:

Engine component replacement (e.g., water pump, alternator), transmission service, brake caliper/wheel cylinder replacement, power steering pump replacement, suspension component replacement, exhaust system repair

Diagnostic Procedures:

Troubleshooting charts, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics, wiring diagram analysis for electrical issues

Special Procedures:

Timing belt replacement (if applicable), airbag system servicing, anti-lock braking system (ABS) bleeding, fuel system pressure testing, emissions system diagnostics

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds)

📊 Manual Specifications

File Format

Searchability:

Fully searchable text

Accessibility:

Printable pages

Print Quality

Image Resolution:

High-resolution for clear exploded views and diagrams

Binding Type

Binding:

Not Applicable (Digital Format)

Paper Type

Paper Quality:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Engine Description 1:

3.3L (3301cc) OHV V6

Bore X Stroke 1:

3.90 in x 3.58 in (99.0 mm x 91.0 mm)

Compression Ratio 1:

8.9:1

Horsepower 1:

180 hp @ 5000 rpm

Torque 1:

205 lb-ft @ 3200 rpm

Optional Engine

Engine Code 2:

Engine Description 2:

2.4L (2429cc) DOHC I4 (less common in US market for 2002)

Horsepower 2:

150 hp @ 5800 rpm

Torque 2:

167 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Fuel Octane Requirement:

87 octane (minimum recommended)

🔧 Transmission

Standard Transmission

Type:

4-speed Automatic Transaxle (41TE/42LE)

Optional Transmission

Type:

5-speed Manual Transaxle (NV1500) - rare for North American models

Features

Electronic Control:

Yes, for automatic transmission

Fluid Type

Automatic Transmission Fluid:

Chrysler ATF+4 (MS-9602)

Fluid Capacity

Automatic Transmission Fluid Capacity:

Approx. 3.5 quarts (3.3 liters) for drain and fill

📐 Dimensions

Exterior

Length:

Approx. 179.5 inches (4559 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 68.1 inches (1730 mm)

Wheelbase:

Approx. 111.9 inches (2842 mm)

Cargo

Cargo Volume Behind First Row:

Approx. 146.5 cu ft (4148 L)

Cargo Volume Behind Second Row:

Approx. 85.4 cu ft (2418 L)

Weights

Curb Weight:

Approx. 3900-4100 lbs (1769-1860 kg) depending on configuration

Gross Vehicle Weight Rating:

Approx. 5500 lbs (2495 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

★★★★★ (5 Stars) for 2002 model year

NHTSA Front Impact Passenger:

★★★★★ (5 Stars) for 2002 model year

IIHS Side Impact:

Good (for models equipped with side airbags)

Active Features

Standard on most models

Traction Control:

Optional on some trims

Passive Features

Airbags Front:

Driver and passenger front airbags standard

Airbags Side:

Optional side-impact airbags for front occupants

Seatbelts:

3-point seatbelts in all seating positions, shoulder belt height adjustment

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, cassette tape player (optional), and up to 6 speakers

Rear Entertainment:

Optional rear-seat video system with built-in screen

Driver Assistance

Cruise Control:

Standard on most trims

Parking Sensors:

Not typically available for this model year

Connectivity

Remote Keyless Entry:

Optional

Power Accessories:

Power windows, power door locks, power mirrors were common options

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 7,500 miles (5,000 - 12,000 km) or 6 months, depending on driving conditions and oil type used (refer to manual for specifics)

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km)

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km)

Spark Plug Replacement:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (e.g., platinum vs. iridium)

Transmission Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km)

Fluid Specifications

Engine Oil:

SAE 5W-30, API SN or higher (check manual for exact spec)

Coolant:

Chrysler OAT (Organic Additive Technology) coolant, 50/50 mix with distilled water

Brake Fluid:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or ATF+4 (check manual)

Known Issues

Common Problem 1:

Rear axle seal leaks

Common Problem 2:

Ignition coil failure (leading to misfires)

Common Problem 3:

Transmission solenoid issues (affecting shifting)

Common Problem 4:

Water pump leaks

Common Problem 5:

Power window motor failure

Common Problem 6:

CV joint wear

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge has a long history of producing durable and practical vehicles, particularly trucks and vans.

Model Evolution

Caravan Introduction:

The Dodge Caravan (and its Plymouth Voyager sibling) pioneered the minivan segment in 1984.

Generation 2002:

The 2002 model year falls within the second generation (NS, 1996-2000) and the beginning of the third generation (RS, 2001-2007). The 2002 model specifically refers to the RS generation.

Key Updates Rs Generation:

Improved aerodynamics, stiffer body structure, updated interior, available rear-seat entertainment, enhanced safety features.

Production

Manufacturing Plant:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)

Production Years:

1984-2007 (for Caravan nameplate, various generations)

🏆 Awards & Recognition

Recognitions

Initial Reception:

Generally well-received for its practicality and value at launch.

Long Term Reliability:

Mixed; while popular, some model years and components are known for specific issues that require maintenance.