2002 Dodge Grand Caravan Service and Repair Manual

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Factory-Grade Data

2002 Dodge Grand 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

  • EL Mini Passenger Van 4-Door
  • ES Mini Passenger Van 4-Door
  • SE Mini Passenger Van 4-Door
  • Sport Mini Passenger Van 4-Door
  • EX Mini Passenger Van 4-Door

Engines covered

  • 3.3L 3301CC 201Cu. In. V6 FLEX OHV Naturally Aspirated
  • 3.3L 3301CC 201Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.8L 3778CC 231Cu. 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

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Vehicle Safety Data

2002 Dodge Grand Caravan Recalls & Complaints

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 #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 #10223854

Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean

TSB #10220099

Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.

TSB #10220101

Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.

Showing the 8 most recent of 15 technical service bulletins on file with NHTSA.

20060531Component: FUEL SYSTEM, GASOLINECrash reportedFire reported4 injured

ON JULY 4, 2002 MY 2002 DODGE GRAND CARAVAN WAS INVOLVED IN A LOW SPEED ROLLOVER IN WHICH THE VEHICLE CAME TO REST UPSIDE DOWN. IN THE MINUTES FOLLOWING THE ROLLOVER THE VEHICLE CAUGHT ON FIRE AND B

20050613Component: ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASHCrash reportedFire reported

I EXPERIENCED RAMDOM FAILURE OF THE HEADLIGHTS ON MY DODGE CARAVAN. I BROUGHT THIS TO THE ATTENTION OF MY DEALER AND THEY SAID THEY "COULD NOT DUPLICATE CONCERN". I WAS TOLD THE CAUSE WAS PROBABLY T

20041108Component: AIR BAGS:FRONTALCrash reported2 injured

DURING A 40 MPH FRONT END VEHICLE COLLISION FRONT AIR BAGS DID NOT DEPLOY. CONSUMER SUSTAINED INJURIES. VEHICLE WAS TOWED. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK

20040831Component: STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDSCrash reported2 injured

VEHICLE WAS MOVING AT APPROXIMATELY 5 MPH AND HIT A POLE. THE IMPACT FROM THE POLE DAMAGED THE FRAME OF THE VEHICLE. CONSUMER HAS A CONVERSION VAN TO ACCOMODATE A WHEEL CHAIR PASSENGER. BOTH THE DRIVE

20060225Component: AIR BAGSCrash reported1 injured

ACCIDENT, GRAND CARAVAN WAS TOTALED. VAN FLIPPED, EXTENSIVE FRONT END, FRAME, SIDE, ROOF, ETC, DAMAGE. NEITHER OF THE FRONT AIR BAGS DEPLOYED, NOR DID THE SIDE AIR BAGS. PRELIMINARY ASSESSMENTS, INCLU

Showing the 5 most serious of 417 complaints filed with NHTSA.

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