2002 Dodge Caravan Service and Repair Manual

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Covers all 2002 Caravan trims — Ec Mini Passenger Van 4-Door, SE Mini Passenger Van 4-Door, Sport Mini Passenger Van 4-Door +1 more ·
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2002 Dodge Caravan service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Ec Mini Passenger Van 4-Door
  • SE Mini Passenger Van 4-Door
  • Sport Mini Passenger Van 4-Door
  • Base Mini Passenger Van 4-Door

Engines covered

  • 2.4L 2429CC 148Cu. In. l4 GAS DOHC Naturally Aspirated
  • 3.3L 3301CC 201Cu. In. V6 FLEX OHV Naturally Aspirated
  • 3.3L 3301CC 201Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #03E04500026/09/2003Component: EQUIPMENT

AFTERMARKET REPLACEMENT FUEL FILTERS MANUFACTURED BETWEEN SEPTEMBER 17, 2002, AND JANUARY 20, 2003, SOLD UNDER THE BRAND NAMES LISTED ABOVE. THE FILTER MAY EXPERIENCE MALFUNCTION OF THE QUICK CONNEC

Consequence

IF THIS CONDITION OCCURRED WHILE THE VEHICLE IS IN MOTION, THE ENGINE COULD STALL. ALSO, IN THE PRE

Remedy

AFTERMARKET REPLACEMENT FUEL FILTERS FOR 1995-2000 SHORT WHEELBASE CHRYSLER TOWN & COUNTRY, PLYMOUTH

NHTSA #03E05300024/10/2003Component: FUEL SYSTEM, GASOLINE

CERTAIN AFTERMARKET REPLACEMENT FUEL FILTERS, MODELS WIX FILTER PART NUMBERS 33576, 33577, 33734; NAPA FILTER PART NUMBERS 3576, 3577, 3734; AND CARQUEST FILTER PART NUMBERS 86576, 86577, 86734 USED O

Consequence

A POSSIBLE FIRE CAN OCCUR IN THE PRESENCE OF AN IGNITION SOURCE.

Remedy

WIX WILL NOTIFY ITS CUSTOMERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. NOTE: THIS DOES NOT I

NHTSA #06E02200013/03/2006Component: SERVICE BRAKES, HYDRAULIC

CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAN

Consequence

LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTAN

Remedy

AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE

NHTSA #10E03400010/08/2010Component: EQUIPMENT

CURT MFG IS RECALLING CERTAIN CLASS 3 RECEIVER HITCHES, P/N 13347, SOLD AS AFTERMARKET EQUIPMENT FOR USE ON 1997-2007 CHRYSLER TOWN AND COUNTRY VANS, 1996-2007 DODGE CARAVANS, AND 1996-2004 PLYMOUTH V

Consequence

IF THE AREA IN QUESTION FRACTURES OR BREAKS, THIS COULD CAUSE AN UNSTABLE DRIVING CONDITION, POSSIBL

Remedy

CURT MFG WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE THE HITCH FREE OF CHARGE. THE SAFETY RECALL

NHTSA #08E04800008/08/2008Component: EXTERIOR LIGHTING:HEADLIGHTS

EAGLE EYES IS RECALLING 11,534 HEADLAMP ASSEMBLIES, P/NOS. CS090-B001L AND CS090-B001R, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

EAGLE EYES WILL NOTIFY OWNERS AND OFFER REPLACEMENT HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN ON S

NHTSA #03V09400007/03/2003Component: STRUCTURE

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE

Consequence

THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy

DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7,

NHTSA #04V38600005/08/2004Component: STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS

ON CERTAIN MINIVANS EQUIPPED WITH 3.3 OR 3.8L V-6 ENGINE, THE UPPER POWER STEERING COOLER HOSE MAY SPLIT AND CAUSE A FLUID LEAK.

Consequence

POWER STEERING FLUID LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN AN UNDER HOOD FIRE.

Remedy

DEALERS WILL REPLACE THE UPPER POWER STEERING COOLER HOSE. THIS RECALL BEGAN ON SEPTEMBER 27, 2004.

NHTSA #01V31000004/10/2001Component: CHILD SEAT

VEHICLE DESCRIPTION: CERTAIN MINI VANS FAIL TO COMPLY WITH REQUIREMENTS OF FMVSS NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE OWNER MANUALS SUPPLIED WITH THESE VEHICLES DO NOT INDICATE WHICH

Consequence

IN THE EVENT OF A CRASH, THE CHILD SEAT MAY NOT BE PROPERLY ATTACHED INCREASING THE RISK OF INJURY T

Remedy

OWNERS WILL BE PROVIDED WITH THE NECESSARY CHILD RESTRAINT SYSTEM INFORMATION. OWNER NOTIFICATION I

NHTSA #04V53100002/11/2004Component: EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

ON CERTAIN MINI VANS, CONDENSATION FROM THE INSTRUMENT PANEL AIR CONDITIONING DUCTS MAY DROP THROUGH VENT HOLES IN THE TOP OF THE RADIO AND RESULT IN A SHORT CIRCUIT THAT SUBSEQUENTLY SENDS DIRECT CUR

Consequence

THIS COULD RESULT IN A SPEAKER FIRE.

Remedy

DEALERS WILL ADD A SPECIAL TAPE TO THE TOP OF THE RADIO TO PREVENT THE POTENTIAL OF WATER INTRUSION.

TSB #10229256

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10221686

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10191460

Valve Body. These may cause over drive cycling.

TSB #10175735

Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are neces

TSB #10175743

Disinfectant Solution Recommended for COVID-19

TSB #10022182

POWER SLIDING DOOR ADJUSTMENT AND DIAGNOSIS AID. *KB UPDATED 10/26/07. *NJ

TSB #10021668

CLEANING PROCEDURE FOR THE MECHANICAL THROTTLE BODY. *KB

TSB #10021239

POWERTRAIN CONTROL MODULE INITIALIZATION. *KB

Showing the 8 most recent of 92 technical service bulletins on file with NHTSA.

20030327Component: SEATSCrash reported3 injured

THE REASON I'M WRITING THIS IS BECAUSE 'M TRYING TO FIND OUT THE PROPER STEPS TO TAKE TO HAVE AN INVESTIGATION ON THE FAILURE OF THE SEATBELTS AND SEATS. ON THE 16TH OF MARCH 2003 MY FAMILY AND I W

20020731Component: SEATS:FRONT ASSEMBLY:RECLINERCrash reported2 injured

WHILE SLOWING DOWN CONSUMER'S VEHICLE WAS REAR ENDED AT ABOUT 40-45 MPH, AND DRIVER /PASSENGER SEATS COLLAPSED ON IMPACT, CAUSING DRIVER TO FALL ON TO CHILD AND INJURING CHILD, THE PASSENGER IN THE

20050525Component: AIR BAGS:FRONTALCrash reported1 injured

DT: THE CONSUMER'S VEHICLE HIT A SEMI TRAILER AT ABOUT 20 MPH AND THE FRONTAL AIRBAGS DID NOT DEPLOY. THE DRIVER TRIED TO BRAKE, AND THE IMPACT WAS IN THE FRONT OF THE VEHICLE. THE BUMPER WAS MOVED

20050525Component: SEAT BELTS:FRONTCrash reported1 injured

DT: THE CONSUMER'S VEHICLE HIT A SEMI TRAILER AT ABOUT 20 MPH AND THE FRONTAL AIRBAGS DID NOT DEPLOY. THE DRIVER TRIED TO BRAKE, AND THE IMPACT WAS IN THE FRONT OF THE VEHICLE. THE BUMPER WAS MOVED

20041012Component: AIR BAGSCrash reported1 injured

I HAD PURCHASED A 2002 DODGE CARAVAN SE AND IMMEDIATELY AFTER IT WAS BACK IN THE SHOP FOR REPAIRS. I HEARD A NOISE IN THE WINDOW AND THE DODGE PLACE TOLD ME IT WAS NOTHING NOT TO WORRY ABOUT IT. ALSO

Showing the 5 most serious of 326 complaints filed with NHTSA.

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