2002 Dodge Caravan Repair Manual
Technician-level documentation for the 2002 Dodge Caravan, covering all models and variations. Documents engine, transmission, brakes, suspension, and electrical systems
Dodge Models Covered & Key Technical Specifications
Models: Dodge Caravan, Chrysler Town & Country, Chrysler Voyager, Chrysler Grand Voyager
Sub-models / Variants: FWD, AWD, Short Wheel Base, Long Wheel Base, 3-Speed Automatic Transaxle, 4-Speed Electronic Automatic Transaxle, 5-Speed Manual Transaxle
Model Years: 2002
Technical Data:
- Engine Options: 2.4L 16-Valve DOHC, 3.3L SMPI V6, 3.8L SMPI V6, 3.3L Ethanol Flexible Fuel, 2.5L 16-Valve Turbo Diesel
- Cooling System Capacity: 10.7 L (2.4L), 12.6 L (3.3L/3.8L without auxiliary heater), 15.4 L (3.3L/3.8L with auxiliary heater)
- Automatic Transaxle Fill (31TH/41TE): 8.6 L / 9.2 L (Overhaul fill)
- Manual Transaxle (T850) Oil Capacity: 2.4–2.7 L
- Wheel Mounting Nut Torque: 135 N·m (100 ft. lbs.)
- Front Hub And Bearing Mounting Bolt Torque: 65 N·m (45 ft. lbs.)
- Front Hub/Axle Nut Torque: 244 N·m (180 ft. lbs.)
Dodge Manual Features & Content Preview
2002 Dodge Caravan & Chrysler Town & Country Factory Service Documentation
- Covers 2002 Dodge Caravan, Chrysler Town & Country, Voyager, and Grand Voyager models (FWD, AWD, short and long wheelbase variants).
- Official DaimlerChrysler OEM publication (PN 04507248aa) detailing engine, suspension, drivetrain, and electrical systems.
- Features 47 high-detail exploded-view diagrams and 51 critical torque specification tables for accurate chassis and drivetrain maintenance.
- Fully searchable OCR text layer allows rapid keyword navigation directly to specific fastener specs or component references.
- Instant download provides immediate shop-floor access to the exact technical data and factory-standard torque settings required for the 2002 platform launch build.
Component Documentation Scope
This 100-page edition maps out the exact technical specifications and component identifiers needed to understand the front and rear suspension, half shafts, and cooling systems. Major sections break down the MacPherson strut front suspension alongside both multi-leaf and mono-leaf rear spring configurations. Mechanics will find clear structural distinctions between FWD and AWD drivetrain architectures. The documentation outlines component details for hub and bearing assemblies, stabilizer bars, and track bar setups. It also covers cooling system parameters, highlighting precise fluid capacities and required antifreeze types strictly tailored for aluminum engine components.
Specification and Reference Highlights
Accurate technical data is crucial for keeping these minivans within factory parameters. You get exact fastener requirements directly from the manufacturer. For example, front strut-to-knuckle bolts are specified at 81 N·m (60 ft. lbs.) plus a 90-degree turn, while rear hub and bearing bolts require 129 N·m (95 ft. lbs.). The text details specific system capacities, noting the power steering system at 1.2 L (2.5 pts) and Suzuki-based or similar transmission fluid capacities at 8.6–9.2 L for an overhaul. Valvetrain details outline an intake valve clearance of 0.11–0.20 mm. Furthermore, fuel system requirements for ethanol-capable engines are documented alongside turbo diesel cooling capacities of 13.8 L. Keep in mind that this documentation serves as a professional reference guide; always verify standard shop safety protocols and consult a certified technician before performing major vehicle modifications or service work.
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