2002 Dodge Caravan Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2002 Vehicle Type: Minivan 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families, fleet operators, automotive repair shops Competitive Analysis...

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类型: Caravan

斯库: 440354

标签: 2002 Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Vehicle Type:

Minivan

👋 Introduction

Market Position

Segment:

Mid-size Minivan

Target Audience:

Families, fleet operators, automotive repair shops

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture

Key Features

Vehicle Strengths:

Spacious interior, versatile seating configurations, practical for family transport, often equipped with Stow 'n Go seating (later models, but foundational to the Caravan's appeal)

Manual Value

Benefit To Owner:

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

Benefit To Technician:

Provides accurate, manufacturer-specific procedures for efficient and correct repairs

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for the 2002 Dodge Caravan

Engine Coverage:

2.4L I4, 3.3L V6, 3.8L V6

Transmission Coverage:

Automatic Transmissions (4-speed)

Electrical Coverage:

Extensive diagnosis and repair of all electrical systems, including wiring diagrams

Chassis Coverage:

Suspension, steering, brakes, exhaust, fuel system

Body Coverage:

Body and chassis repair, doors, interior trim, climate control

Page Count

Estimated Page Count:

~2000+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete teardown, inspection, and reassembly of all engine components (pistons, rings, valves, camshafts, crankshafts, cylinder heads, blocks)

Engine Performance:

Fuel injection systems, ignition systems, emissions control systems, turbocharging (if applicable), engine control module (ECM) operation and diagnostics

Transmission Overhaul:

Detailed procedures for automatic transmission repair, including valve bodies, torque converters, clutch packs, planetary gears

Braking System:

Hydraulic system diagnosis, ABS operation, brake pad/rotor replacement, caliper service, parking brake adjustments

Suspension Steering:

Struts, shocks, control arms, ball joints, tie rods, power steering system, wheel alignment procedures

HVAC System:

Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser service, heater core replacement

Body Electrical:

Lighting, power windows, power locks, door mechanisms, sunroof operation, instrument cluster diagnostics

Diagnostic Troubleshooting:

Systematic approach to diagnosing common and intermittent faults using diagnostic trouble codes (DTCs) and scan tool data

Procedures Included

Maintenance:

Oil changes, filter replacements, tune-ups, fluid checks and replacements, belt and hose inspections

Repair:

Component replacement, engine rebuilds, transmission rebuilds, suspension and brake repairs, electrical component repair

Troubleshooting:

Step-by-step diagnostic guides for various symptoms and fault conditions

Diagnostics:

In-depth diagnostic procedures for all major vehicle systems, including PCM/ECM diagnostic codes

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and advanced DIYers

Diagnostics Level:

Advanced diagnostic strategies, including sensor data interpretation and component testing

Rebuild Procedures:

Complete rebuild procedures for major mechanical components like engines and transmissions

📊 Manual Specifications

File Format

Format:

Searchable PDF

Print Quality

Resolution:

High-resolution, suitable for on-screen viewing and printing

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

Searchability

Search Functionality:

Full text search capability for quick information retrieval

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.4L DOHC Inline-4 ( = 2378 cc)

Engine 1 Power:

150 hp @ 5800 rpm

Engine 1 Torque:

170 lb-ft @ 4000 rpm

Optional Engine

Engine 2:

3.3L OHV V6 ( = 3301 cc)

Engine 2 Power:

180 hp @ 5000 rpm

Engine 2 Torque:

205 lb-ft @ 3600 rpm

Engine 3:

3.8L OHV V6 ( = 3778 cc)

Engine 3 Power:

200 hp @ 5200 rpm

Engine 3 Torque:

232 lb-ft @ 3200 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with individual ignition coils

Emission Controls

Emission System:

Catalytic converter, Oxygen sensors (O2S), EGR (Exhaust Gas Recirculation)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transmission (41TE)

Optional

Optional Transmission:

Not typically applicable for this year; primarily automatic

Features

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approx. 11.0 quarts (10.4 liters) - check manual for precise refill amount

Transmission Control:

Electronically controlled with overdrive

📐 Dimensions

Exterior

Wheelbase:

119.3 inches (3030 mm)

Length:

189.8 inches (4821 mm)

Width:

72.0 inches (1829 mm)

Height:

66.4 inches (1687 mm)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 32.0 cubic feet (0.91 cubic meters)

Cargo Volume Behind 2Nd Row:

Approx. 76.5 cubic feet (2.17 cubic meters)

Cargo Volume Max:

Approx. 140.5 cubic feet (3.98 cubic meters)

Weights

Curb Weight Min:

Approx. 3800 lbs (1724 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5600 lbs (2540 kg) - varies by engine and configuration

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

Good (for 2002 model year, depending on specific tests)

NHTSA Frontal Passenger:

Good (for 2002 model year, depending on specific tests)

NHTSA Side Impact Driver:

Acceptable/Good (for 2002 model year, depending on specific tests)

NHTSA Side Impact Rear Passenger:

Acceptable/Good (for 2002 model year, depending on specific tests)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional traction control system

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front-seat side-impact airbags

Seatbelts:

3-point seat belts for all seating positions, front seat pretensioners

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette and CD player options. Optional Infinity sound system.

Navigation:

Not commonly available or advanced in this model year; typically aftermarket units.

Driver Assistance

Cruise Control:

Standard or optional cruise control

Parking Sensors:

Optional rear parking assist sensors

Connectivity

Auxiliary Input:

Not typically equipped with standard aux-in or USB ports; aftermarket solutions available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (consult manual for specific recommendations).

Engine Air Filter:

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

Cabin Air Filter:

Replace every 12,000-15,000 miles (19,000-24,000 km) or annually.

Spark Plugs:

Replace at 100,000 miles (160,000 km) for platinum/iridium plugs (standard for most 2002 models).

Transmission Fluid Service:

Flush and replace every 60,000-100,000 miles (96,000-160,000 km) or as specified in the manual.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (for most conditions), SAE 10W-30 (in very mild temperatures). Consult owner's manual for exact spec based on engine.

Coolant Type:

Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, Orange (50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 (or DOT 4 if specified).

Power Steering Fluid:

ATF+4 or specific Mopar power steering fluid.

Known Issues

Common Issues 1:

Transmission solenoid failures and torque converter issues (especially on higher mileage vehicles).

Common Issues 2:

Cracked exhaust manifolds (especially on V6 engines).

Common Issues 3:

Power door lock actuators and sliding door issues.

Common Issues 4:

Rear suspension sag or noise, often requiring replacement of springs or shocks.

Common Issues 5:

Evaporative emission control system (EVAP) leaks, often due to faulty vent valve or gas cap.

📚 Vehicle History

Brand Heritage

Dodge Heritage:

Dodge, a division of Chrysler (now Stellantis), has a long history of producing practical and powerful vehicles, including its significant contribution to the minivan segment.

Model Evolution

Minivan Origin:

The Dodge Caravan, along with its Plymouth Voyager counterpart, pioneered the minivan segment in the 1980s, revolutionizing family transportation.

Third Generation:

The 2002 model belongs to the third generation of the Dodge Caravan (1996-2007), which saw significant redesigns in styling and technology.

Production

Manufacturing Plant:

Primarily Windsor, Ontario, Canada and St. Louis, Missouri, USA.

Production Years

Model Run:

1984-2020 (Dodge Caravan/Grand Caravan nameplate)

🏆 Awards & Recognition

Recognitions

Segment Popularity:

Consistently a top-selling minivan, recognized for its value and practicality.

Ratings

Consumer Reports Ratings:

Variable depending on year and specific components, often rated as average for predicted reliability in this era.

Certifications

Safety Certifications:

Meets all U.S. federal motor vehicle safety standards (FMVSS) for the 2002 model year.