Dodge Caravan & Chrysler Town & Country 2002 Factory Service Manual Set (P/N 81-370-02062)

The service manual supplies mechanical repair procedures, while the diagnostic volumes provide fault-isolation tests and post-repair verification. Select the appropriate volume for the installed engine, transaxle, and equipment; the gas powertrain book’s additional model-year coverage does not extend the entire set.

PDF Search, Bookmarks, and Diagram Detail

Search and schematic labels: Running text is searchable, but some wiring-diagram lettering is not. All six technical manuals contain chapter bookmarks; the main service manual’s root bookmark opens the comments form, so use its individual chapter entries. Small schematic labels require zooming. Keep the original filenames and folder layout for links between PDFs.

The ZIP contains 8 printable PDFs totaling 4,426 pages. That total already includes the two title/foreword pages, one selection-screen page, 33 blank divider pages, 17 notes pages, and two service-comment pages. Two TSB-corrected wiring pages are included in the service manual.

Engine Overhaul, AWD Service, and Circuit Diagnosis

These selected coverage highlights outline the main workshop material rather than reproduce the full contents. Other topics include stationary-glass replacement and diesel supplemental-heater service.

• Engine repair: Step-by-step removal and installation, cylinder-head and valvetrain service, internal inspection, lubrication-system repair, and timing-drive procedures for gasoline and turbo-diesel engines.

• Transaxles and AWD: Automatic and manual transaxle teardown, inspection, reassembly, and adjustment, plus power transfer unit, rear driveline module, propeller-shaft, half-shaft, and CV-joint service.

• Suspension and steering: MacPherson struts, control arms and bushings, steering knuckles, hubs and bearings, rear leaf springs, stabilizer bars, wheel alignment, and power steering.

• Brakes and chassis controls: Base-brake repair, Teves Mark 20 ABS and traction-control diagnosis, and adjustable-pedal system testing.

• Electrical and body systems: DRB III fault testing for PCM/ECM controls, airbags, HVAC, tire-pressure monitoring, theft security, power sliding doors, and the power liftgate.

• Factory reference data: Torque tables, fluid capacities and approved fluids, pressure-test specifications, wear limits, clearances, electrical test values, exploded views, and component sections.

Written for professional automotive technicians performing daily repair work, the material includes diagnostic procedures that require a DRB III scan tool and specialist service equipment.

Gasoline and Turbo-Diesel Engine Repair

Gasoline engines: The 2.4L material covers camshafts, hydraulic lash adjusters, rocker arms, balance shafts, the oil pump, pistons, crankshaft, and timing belt. The 3.3L/3.8L sections address the cam-in-block valvetrain, lifters, timing chain, intake and exhaust manifolds, and lubrication system. Flexible-fuel requirements are also documented.

Diesel-specific work: Coverage includes common-rail fuel-system diagnosis, cylinder liners and pistons, camshaft and crankshaft inspection, timing-position locking, timing-belt tensioning, the oil cooler, and piston cooling jets. Piston-protrusion measurements are tied to cylinder-head gasket selection.

Turbocharger removal, cleaning, and installation are documented. The specified removal procedure requires the engine to be removed from the vehicle.

Cooling chapters provide system diagnosis, coolant selection, flow checks, and component service for the gasoline and diesel configurations.

Transaxles, Clutch, and AWD Driveline

The 31TH and 41TE sections cover clutch assemblies, pumps, valve bodies, planetary gearing, final drives, differentials, and torque-converter diagnosis. Electronic controls, sensors, and solenoids are addressed where applicable.

The T850 chapter covers shift cables, shafts, synchronizers, differential components, teardown, reassembly, and adjustment. Separate clutch sections distinguish the gasoline modular clutch from the diesel clutch disc and pressure plate.

AWD repair material covers the power transfer unit, rear driveline module, viscous coupler, propeller shaft, seals, bearings, and rear half shafts. Front CV-joint material includes boot replacement and inspection; worn internal half-shaft components identified as nonserviceable require assembly replacement.

Suspension Layouts and Alignment

Chassis chapters distinguish FWD and AWD rear layouts, mono-leaf and multi-leaf springs, and their hub, spring, stabilizer, shock, and half-shaft procedures. The FWD track bar is covered separately.

Wheel-alignment information explains camber, caster, toe, thrust angle, curb height, and pre-alignment inspection. These distinctions support selection of the correct procedure before suspension parts are removed or alignment settings are assessed.

Fault Testing and Wiring References

The diagnostic books organize faults by conditions, possible causes, pinpoint tests, and verification procedures rather than code definitions alone. Body-control testing includes communication faults, connector pinouts, component locations, and lab-scope patterns.

Transmission electronics: The 41TE/AE volume includes AutoStick diagnosis, Quick Learn, clutch-volume information, pressure-port identification, solenoid application, pressure-switch states, and transmission-range-sensor data. It describes the Miller Transmission Simulator 8333 with FWD Adapter 8333-1 for separating electrical-control faults from internal transmission problems.

Gas powertrain procedures address PCM, SKIM, and ignition-key programming where applicable. Diesel diagnostics cover the common-rail system, no-start conditions, and communication faults.

Electrical references include 8W-10 Power Distribution, 8W-31 Transmission Control, 8W-35 Antilock Brakes, 8W-42 Air Conditioning-Heater, and 8W-43 Airbag System, alongside power sliding-door and power-liftgate schematics. Connector views, splice locations, and ground locations support circuit tracing.

Component-Specific Service Cautions

The rear-suspension section warns that hammering a seized AWD rear hub/bearing can damage the assembly and cause noise or failure. FWD rear hub removal is documented with Special Tool 8458.

Cooling instructions warn that mixing incompatible coolant types reduces corrosion protection and can cause premature water-pump seal failure.

Airbag, brake, fuel, refrigerant, rotating machinery, and hoisted-vehicle work should be approached with the factory safety precautions, suitable service equipment, and appropriate experience. Use this set as the repair reference; it does not replace safe vehicle support, system isolation, or proper fuel and refrigerant handling.

Selected Front-Strut Tightening Specifications

The front-suspension torque table specifies 81 N·m (60 ft. lbs.) plus a 90-degree turn for the strut clevis-to-knuckle nuts. The strut shaft nut is listed separately at 100 N·m (75 ft. lbs.), distinguishing the shaft fastening specification from the knuckle attachment.