Dodge Caravan 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Codes Chassis Code: NS (Third Generation) 👋 Introduction Market Position Segment: Mid-size Minivan Historical Significance: A highly successful and popular...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Chassis Code:

NS (Third Generation)

👋 Introduction

Market Position

Segment:

Mid-size Minivan

Historical Significance:

A highly successful and popular model in its segment, known for practicality and family-oriented design.

Competitive Analysis

Key Competitors 2002:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza, Plymouth Voyager (corporate sibling).

Key Features

Defining Characteristics:

Spacious interior, versatile seating configurations (e.g., Stow 'n Go in later generations, but 2002 offered flexible seating), comfortable ride, front-wheel drive or all-wheel drive availability.

Target Audience:

Families, individuals requiring cargo space, fleet operators.

📋 Manual Details

Coverage Areas

Market Coverage:

North America (USA, Canada, Mexico)

Region Specific Notes:

Covers models as sold in primary North American markets; specific regional variations may require supplemental documentation.

All Models Engines Trims:

Transmission Types Covered:

Automatic Transmission (e.g., 41TE/42LE/45RFE) and potentially Manual Transmission (if offered).

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Repair Service Manual

Content Scope:

Comprehensive service, maintenance, and troubleshooting

Language

Language:

English

Format

Format:

PDF Download

File Characteristics:

Searchable, printable

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Drivetrain, Transmission (Automatic and Manual - if applicable)

Chassis:

Suspension (Front and Rear), Steering System, Brake System (Hydraulic and Parking), Wheels and Tires

Electrical:

Body Electrical Systems, Powertrain Control Module (PCM), Engine Control Module (ECM), Powertrain Wiring Diagrams, Lighting, Instrumentation, Audio System, Climate Control System, Power Accessories

Body:

Body and Frame, Exterior Panels, Doors, Windows, Seating Systems, Interior Trim, HVAC System Components

Procedures Included

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements, lubrication, belt and hose inspections.

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, component testing procedures.

Repair:

Component removal and installation, sub-assembly repairs, overhaul procedures, seal and gasket replacement.

Specifications Data:

Torque specifications, clearances, fluid capacities, wiring diagrams, component identification.

Technical Depth

Depth:

Detailed, from basic maintenance to major component overhaul and electrical system diagnosis.

Diagnostic Tools:

References diagnostic procedures and potential use of scan tools for retrieving DTCs and live data.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Scan Resolution:

High-resolution scans ensuring clarity of text and diagrams.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Option 1 Displacement:

3.3L (200 cu in) V6

Engine Option 1 Configuration:

OHV (Overhead Valve) V6

Engine Option 1 Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Engine Option 1 Horsepower:

Approx. 180 hp @ 5000 rpm

Engine Option 1 Torque:

Approx. 205 lb-ft @ 3200 rpm

Secondary Engine

Engine Option 2 Displacement:

3.8L (230 cu in) V6

Engine Option 2 Configuration:

OHV (Overhead Valve) V6

Engine Option 2 Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Engine Option 2 Horsepower:

Approx. 200-215 hp @ 5000 rpm

Engine Option 2 Torque:

Approx. 225-235 lb-ft @ 3200 rpm

Performance

Emission Control:

Catalytic Converter, On-Board Diagnostics (OBD-II)

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 20 gallons (75.7 liters)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transmission

Optional

Transmission Options:

All-wheel drive (AWD) available with certain engine configurations and trims.

Features

Transmission Control:

Electronically Controlled Transmission (ECT)

📐 Dimensions

Exterior

Wheelbase:

Approx. 113.3 inches (2878 mm)

Overall Length:

Approx. 189.8 inches (4821 mm)

Overall Width:

Approx. 72.4 inches (1839 mm)

Overall Height:

Approx. 67.9 inches (1725 mm)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 15.0 - 20.0 cu ft (depending on configuration)

Cargo Volume Behind 2Nd Row:

Approx. 75.0 - 90.0 cu ft (depending on configuration)

Cargo Volume Max:

Approx. 140.0 - 160.0 cu ft (depending on configuration)

Weights

Curb Weight:

Approx. 3800 - 4200 lbs (1724 - 1905 kg) depending on configuration

Gross Vehicle Weight Rating:

Approx. 5300 - 5600 lbs (2404 - 2540 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (for 2002 models)

NHTSA Front Impact Passenger:

4 Stars (for 2002 models)

NHTSA Side Impact Front Driver:

4 Stars (for 2002 models)

NHTSA Side Impact Front Passenger:

4 Stars (for 2002 models)

NHTSA Side Impact Rear Driver:

3 Stars (for 2002 models)

NHTSA Side Impact Rear Passenger:

3 Stars (for 2002 models)

Active Features

Standard on most models

Traction Control:

Optional on some models

Passive Features

Airbags:

Driver and front passenger airbags standard; optional side airbags available on some trims.

Seatbelts:

Three-point seatbelts in all seating positions.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio systems, available rear-seat entertainment (RSE) on some trims.

Climate Control:

Manual A/C and heater standard, optional automatic climate control available on higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Assistance:

No factory-installed parking sensors or rearview cameras.

Connectivity

Connectivity Options:

Limited to auxiliary inputs for aftermarket audio devices, no integrated Bluetooth or USB ports from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Recommended every 3,000 to 7,500 miles (5,000 to 12,000 km) or 3-6 months, depending on oil type and driving conditions (refer to manual for specific guidance).

Tire Rotation:

Recommended every 5,000 to 7,500 miles (8,000 to 12,000 km)

Engine Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or approximately every 30,000 miles (48,000 km).

Spark Plug Replacement:

Typically around 100,000 miles (160,000 km) for platinum-tipped plugs, but consult manual for exact interval and type.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified)

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) with filter for 3.3L/3.8L V6

Coolant Type:

Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, typically pink or orange.

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid +4)

Power Steering Fluid Type:

Mopar Power Steering Fluid or equivalent ATF+4

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Items:

Ball joints, tie rod ends, wheel bearings, exhaust system components (muffler, catalytic converter), alternator, A/C compressor.

Transmission Concerns:

Some models may experience issues with the transmission valve body or solenoids, especially at higher mileage.

Engine Mounts:

Engine mounts can degrade over time, leading to vibrations.

Electrical Gremlins:

While generally reliable, some electrical issues can arise, often related to grounding points or aging wiring harnesses.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge has a long history of producing robust and practical vehicles, particularly trucks and vans, establishing a reputation for value and utility.

Model Evolution

Generation 2002:

Third generation (NS body style), introduced for the 1996 model year, with facelifts and updates continuing through 2007. The 2002 model represents a refinement of this successful platform.

Platform Sharing:

Shared platform and many components with Chrysler Town & Country and Plymouth Voyager/Grand Voyager.

Production

Assembly Locations:

Primarily Windsor, Ontario, Canada; also St. Louis, Missouri, USA.

Production Span:

1984-2007 (for Dodge Caravan nameplate in North America, though the specific NS platform ran from 1996-2007).

🏆 Awards & Recognition

Recognitions

Segment Awards:

The Dodge Caravan (and its siblings) frequently appeared on 'best of' lists for minivans during its production run, recognized for practicality and value.

Ratings

Consumer Reports Ranking:

While rankings varied year to year, the Caravan was generally considered a solid, value-oriented choice within its segment, though sometimes ranked lower than Japanese competitors in predicted reliability.

Certifications

Epa Fuel Economy:

Approx. 17 MPG city / 23 MPG highway for 3.3L FWD model (EPA estimates vary based on driving conditions and specific vehicle configuration).