Dodge Caravan 2002 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Codes Chassis Code: RS Body Style 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size Minivan Target Audience For Manual: DIY mechanics,...

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标签: 2002 Car Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Chassis Code:

RS Body Style

👋 Introduction

Market Position

Vehicle Segment:

Compact/Mid-size Minivan

Target Audience For Manual:

DIY mechanics, independent repair shops, fleet maintenance personnel

Competitive Analysis

Key Competitors 2002:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture

Key Features

Vehicle Selling Points:

Spacious interior, versatile seating configurations, comfortable ride, family-oriented features

Manual Value Proposition:

Empowers owners to perform their own maintenance and repairs, saving significant costs compared to dealership or independent shop labor.

📋 Manual Details

Coverage Areas

Primary Coverage:

2002 Dodge Caravan

Engine Variants Covered:

3.3L V6 (EGA), 3.8L V6 (GVA)

Transmission Variants Covered:

4-speed Automatic (41TE, 42LE)

Page Count

Estimated Page Count:

Approximately 2000+ pages (typical for WSM)

Manual Type

Manual Type:

Workshop Service Manual (WSM) / Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, component testing, diagnosis, specifications

Engine Performance:

Fuel injection, ignition system, emissions control, exhaust system

Transmission Mechanical:

Overhaul, diagnostic procedures, valve body, torque converter

Transmission Electronic:

Transmission control module (TCM) diagnostics, solenoid testing, sensor data

Brake System:

Hydraulic system, ABS (Anti-lock Braking System) components and diagnosis, parking brake

Suspension System:

Front and rear suspension components, alignment procedures, shock absorber/strut replacement

Steering System:

Power steering system diagnosis and repair, steering column, tie rods

Electrical System Charging:

Alternator, battery, voltage regulator

Electrical System Starting:

Starter motor, starter solenoid, ignition switch

Lighting System:

Headlamps, tail lamps, interior lighting, bulb replacement

HVAC System:

Air conditioning, heating, ventilation, blower motor, refrigerant system

Body And Chassis:

Body panels, doors, hinges, latches, interior trim, chassis components

Restraint Systems:

Airbag system diagnosis and replacement, seat belts

Power Accessories:

Power windows, power locks, power mirrors, power seats

Diagnostics:

OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), scan tool usage

Procedures Included

Maintenance:

Oil changes, fluid flushes, filter replacements, spark plug service, belt replacement

Troubleshooting:

Step-by-step diagnostic trees for common and complex issues

Repair:

Component removal and installation, part replacement, adjustments

Overhaul:

Engine and transmission rebuilding procedures

Electrical Diagnosis:

Wiring diagrams, circuit testing, component testing

Diagnostic Tool Usage:

Information on using diagnostic scanners and specific testing equipment

Technical Depth

Depth Of Information:

Comprehensive: Covers routine maintenance to complete engine and transmission overhauls, including detailed diagnostics and repair procedures.

Diagnostic Focus:

Advanced diagnostics, including sensor data interpretation and pinpoint testing.

Repair Detail:

Detailed step-by-step repair instructions with torque specifications and critical measurements.

📊 Manual Specifications

File Format

Digital File Type:

PDF (Portable Document Format)

Print Quality

Scanned Resolution:

High-resolution scans ensuring legibility of text and diagrams.

Binding Type

Digital Format Advantage:

Searchable text, easy navigation via bookmarks and hyperlinks (if digitally created).

Paper Type

Original Manual Paper:

Typically printed on durable, heavy-duty paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Engine Type 1:

3.3L SOHC V6

Displacement 1:

3301 cc (201.5 cubic inches)

Bore X Stroke 1:

93.0 mm x 78.0 mm (3.66 in x 3.07 in)

Compression Ratio 1:

9.0:1

Horsepower 1:

158 hp @ 4600 rpm (SAE Net)

Torque 1:

195 lb-ft @ 3200 rpm (SAE Net)

Optional Engine

Engine Code 2:

Engine Type 2:

3.8L SOHC V6

Displacement 2:

3778 cc (230.5 cubic inches)

Bore X Stroke 2:

93.0 mm x 90.9 mm (3.66 in x 3.58 in)

Compression Ratio 2:

9.0:1

Horsepower 2:

180 hp @ 4400 rpm (SAE Net)

Torque 2:

235 lb-ft @ 3200 rpm (SAE Net)

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane recommended

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with individual ignition coils.

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transaxle

Transmission Codes:

41TE (3.3L), 42LE (3.8L)

Optional

Manual Transmission Availability:

Not available for 2002 Dodge Caravan.

Features

Overdrive:

Yes, all gears (including 4th gear)

Torque Converter Lockup:

Yes, electronically controlled.

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid)

Transmission Fluid Capacity:

Approximately 9.5 - 11.5 quarts (9.0 - 10.9 liters) for complete refill.

📐 Dimensions

Exterior

Wheelbase:

119.3 inches (3030 mm)

Overall Length:

189.4 inches (4811 mm)

Overall Width:

72.0 inches (1829 mm)

Overall Height:

68.4 inches (1737 mm)

Weights

Curb Weight Approximate:

3,800 - 4,100 lbs (1724 - 1860 kg), varies by configuration

Gross Vehicle Weight Rating Gvwr:

Approx. 5,600 lbs (2540 kg)

Cargo

Maximum Cargo Volume:

Approx. 147.5 cu ft (4176 liters) with rear seats removed.

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 out of 5 stars (2002 Model Year)

NHTSA Front Impact Passenger:

4 out of 5 stars (2002 Model Year)

IIHS Frontal Offset Rating:

Good (for most models within this generation, check specific year ratings)

Active Features

Standard on most models, 4-wheel disc brakes available.

Passive Features

Airbags:

Standard front airbags for driver and passenger. Optional side airbags may be available on higher trims.

Seat Belts:

All seating positions equipped with three-point seat belts. Front seat belts with pretensioners.

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with CD player, cassette player. Optional premium audio systems.

Rear Seat Entertainment:

Optional DVD entertainment system with integrated screen available on some trims.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Assistance:

Rear parking assist sensors were an optional feature.

Connectivity

Auxiliary Inputs:

Not typically equipped with standard auxiliary input jacks in this era. Aftermarket solutions may be available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions. Consult manual for specific recommendations.

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Typically every 100,000 miles (160,000 km) for original equipment platinum or iridium plugs. Consult manual for specific plug type and interval.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km). Crucial for longevity; consult manual for exact interval and procedure.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified)

Engine Oil Capacity:

3.8 quarts (3.6 liters) for 3.3L, 4.0 quarts (3.8 liters) for 3.8L (without filter change). Consult manual for capacity with filter.

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, blue color.

Coolant Capacity:

Approx. 13.1 quarts (12.4 liters)

Known Issues

Common Problems Engine:

Intake manifold gasket leaks, occasional head gasket issues (especially on higher mileage examples), oil filter adapter gasket leaks.

Common Problems Transmission:

Erratic shifting, delayed engagement, or transmission slipping can occur, often related to internal wear or solenoid issues. ATF+4 is critical.

Common Problems Electrical:

Faulty power window regulators, power door lock actuators, and sometimes issues with the ignition switch or instrument cluster.

Common Problems Suspension Steering:

Worn tie rod ends, ball joints, and control arm bushings leading to clunking noises or steering looseness.

Common Problems HVAC:

Blend door actuator failures causing improper air temperature control or vent selection issues.

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan/Voyager in the mid-1980s, setting a benchmark for family transport.

Model Evolution

Generation:

Second Generation (1996-2000) - This 2002 model is part of the facelifted second generation, often referred to as the 'RS' body style.

2002 Model Year Updates:

Minor styling updates and feature enhancements compared to earlier models in this generation. Introduction of optional DVD entertainment system.

Production

Manufacturing Location:

Windsor, Ontario, Canada

Production Span For Generation:

1996-2000, with significant facelifts continuing through 2007.

🏆 Awards & Recognition

Recognitions

Initial Reception:

Dodge Caravan and its siblings were consistently praised for their practicality, interior space, and family-friendly features.

Automotive Journal Awards:

Often featured on lists of recommended vehicles by automotive publications for its segment.