Chrysler Dodge Caravan 2002 Minivan Manuals

Manuals and User Guides for Chrysler Dodge Caravan 2002 Minivan. We have 1 Chrysler Dodge Caravan 2002 Minivan manual available for free PDF download: Manual

Chrysler Dodge Caravan 2002 Manual (2399 pages)

Brand: Chrysler | Category: Automobile | Size: 84 MB

Lubrication & Maintenance

14
- Table of Contents
  14
- International Symbols
  
  15
  - Description
    15
    
    Fluid Types Description Description - Engine Oil and Lubricants
    15
    
    Description - Engine Coolant
    16
    
    Oil
    16
    
    Description - Automatic Transmission Fluid
    17
    
    Description - Fuel Requirements
    17
    
    Description - Fuel Requirements - Diesel Engine
    19
- Lubrication & Maintenance
  
  15
- Hoisting
  
  19
- Description - Engine Oil - Diesel Engines
  
  19
- Lubrication & Maintenance
  
  19
- Fluid Fill/Check Locations Description
  
  19
- Lubrication Points Description
  
  19
- Maintenance Schedules Description
  
  19
  - Standard Procedure - Hoisting
    19
- Jump Starting
  
  20
  - Standard Procedure - Jump Starting
    20
- Towing
  
  21
  - Standard Procedure - Towing
    21
Suspension

24
- Front Suspension
  
  25
  - Description - Front Suspension
    25
  - Operation - Front Suspension
    25
  - Standard Procedure - Lubrication
    25
  - Specifications
    26
    
    Front Suspension Fastener Torque
    26
  - Special Tools
    26
    
    Front Suspension
    27
- Bushings
  
  27
- Hub / Bearing Description
  
  27
  - Operation
    27
  - Diagnosis and Testing - Hub and Bearing
    28
  - Removal
    28
  - Installation
    29
  - Removal - Stabilizer Bar Cushion
    27
    
    Installation - Stabilizer Bar Cushion
    27
- Knuckle Description
  
  29
  - Operation
    29
  - Removal - Steering Knuckle
    30
  - Inspection - Steering Knuckle
    31
  - Installation - Steering Knuckle
    32
- Lower Ball Joint Description
  
  33
  - Operation
    33
  - Diagnosis and Testing - Lower Ball Joint
    33
  - Lower Ball Joint Seal Boot
    33
  - Description - Export
    33
  - Removal
    34
    
    Removal - Ball Joint Seal Boot
    34
    
    Removal - Export
    34
- Lower Ball Joint Seal Boot
  
  33
- Front Suspension
  
  34
  - Installation
    34
    
    Installation - Ball Joint Seal Boot
    34
    
    Installation - Export
    35
- Lower Control Arm Description
  
  35
- Stabilizer Bar
  
  39
  - Stabilizer Bar Description
    39
  - Operation
    39
  - Removal
    40
  - Inspection
    40
  - Installation
    41
- Strut
  
  42
Rear Suspension

49
- Operation - Rear Suspension
  50
- Special Tools
  51
  - Rear Suspension
    51
- Specifications
  51
  - Rear Suspension Fastener Torque
    51
- Bushings
  
  52
  - Removal - Leaf Spring Front Bushing
    52
  - Installation - Leaf Spring Front Bushing
    52
- Hub / Bearing Description
  
  53
  - Operation
    54
  - Diagnosis and Testing - Hub and Bearing
    54
  - Removal
    54
  - Installation
    56
- Jounce Bumper Description
  
  59
  - Operation
    59
  - Removal
    59
    
    Removal - Awd and Heavy Duty
    59
    
    Removal - Front-Wheel-Drive
    59
  - Installation
    59
    
    Installation - Awd and Heavy Duty
    59
    
    Installation - Front-Wheel-Drive
    59
- Rear Suspension
  
  60
  - Assembly - Shock Absorber (Upper Bushing)
    61
  - Installation - Shock Absorber
    61
- Shock Absorber Description
  
  60
- Spring - Awd Description
  
  61
  - Operation
    61
  - Removal - Awd
    61
  - Installation - Awd
    62
- Spring - Fwd Description
  
  63
  - Operation
    63
  - Removal - Fwd
    63
  - Installation - Fwd
    64
- Spring Mounts - Front Removal
  
  65
  - Installation
    66
- Spring Mounts - Rear Removal
  
  66
  - Installation
    67
- Stabilizer Bar Description
  
  67
  - Operation
    67
  - Removal
    67
    
    Installation - Awd
    67
    
    Removal - Awd
    67
    
    Removal - Fwd
    67
    
    Installation - Fwd
    68
- Track Bar Description
  
  68
  - Operation
    68
  - Removal
    68
  - Installation
    68
Differential & Driveline

80
- Half Shaft - Front Description
  
  81
  - Removal
    81
  - Installation
    83
  - Specifications - Half Shaft - Front
    85
- Half Shaft - Front
  
  81
- CV Boot - Inner
  
  85
  - Removal
    85
- Half Shaft - Front
  
  85
  - Description
    85
  - Installation
    85
- CV Boot - Outer Removal
  
  89
  - Installation
    89
- Outer CV Joint Bearing Shield Removal
  
  92
  - Installation
    92
Rear Driveline Module

103
- Rear Driveline Module Description
  
  104
  - Diagnosis and Testing Diagnosis and Testing - Rear Driveline Module Noise
    104
  - Diagnosis and Testing - Rear Driveline Module Operation
    106
  - Removal
    106
  - Disassembly
    107
  - Assembly
    109
  - Installation
    113
  - Specifications - Rear Driveline Module
    114
  - Special Tools
    114
- Bi-Directional Overrunning Clutch Description
  
  115
  - Operation
    120
- Differential Assembly Description
  
  120
- Fluid - Differential Assembly
  
  121
  - Standard Procedure - Differential
    121
  - Assembly Fluid Drain and Fill
    121
- Fluid
  
  122
  - Standard Procedure - Overrunning Clutch Housing Fluid Change
    122
- Viscous Coupler Description
  
  123
  - Operation
    123
- Torque Arm Removal
  
  125
  - Installation
    125
- Input Flange Seal Removal
  
  125
  - Installation
    126
- Output Flange Seal Removal
  
  127
  - Installation
    128
Brakes

130
- Brakes - Base
  
  132
  - Description
    132
  - Description - Base Brakes
    132
  - Description - Base Brakes (Export)
    132
  - Operation - Base Brakes
    132
  - Warning
    133
  - Caution
    133
  - Diagnosis and Testing - Base Brake System
    133
  - Standard Procedure - Base Brake Bleeding
    136
  - Specifications
    138
    
    Brake Fastener Torque
    138
  - Special Tools
    138
    
    Base Brake System
    138
- Brake Fluid Level Switch
  
  139
  - Description
    139
  - Operation
    139
  - Removal
    139
  - Installation
    139
- Adjustable Pedal Switch
  
  140
  - Description
    140
  - Diagnosis and Testing - Adjustable Pedal Switch
    140
  - Removal
    140
  - Installation
    141
- Pedal Position Sensor Description
  
  141
  - Diagnosis and Testing - Pedal Position Sensor
    142
  - Removal
    142
  - Installation
    142
- Hydraulic/Mechanical
  
  143
  - Description
    143
    
    Description - Disc Brakes (Front)
    143
    
    Description - Disc Brakes (Export)
    144
    
    Description - Disc Brakes (Rear)
    144
- Brakes - Base
  
  145
  - Description - Drum Brakes (Rear)
    145
  - Operation
    145
    
    Operation - Disc Brakes (Front)
    145
    
    Operation - Disc Brakes (Rear)
    145
  - Diagnosis and Testing - Drum Brake Automatic Adjuster
    145
- Brake Pads/Shoes - Front
  
  146
- Brake Lines
  
  146
- Brake Pads/Shoes - Rear Disc
  
  148
  - Removal - Rear Disc Brake Shoes
    148
  - Cleaning - Disc Brake Shoes
    150
  - Inspection - Disc Brake Shoes
    150
  - Installation - Rear Disc Brake Shoes
    150
- Brake Pads/Shoes - Rear Drum
  
  151
- Disc Brake Caliper - Front
  
  155
  - Removal
    155
    
    (Disc/Disc Brakes)
    155
    
    Removal - Front Disc Brake Caliper
    155
    
    Removal - Front Disc Brake Caliper (Disc/Drum Brakes)
    155
  - Disassembly
    156
    
    Bushings (Disc/Disc Brakes)
    156
    
    Disassembly - Caliper Guide Pin
    156
    
    Disassembly - Caliper Piston and Seal
    156
  - Cleaning - Caliper
    157
  - Inspection - Caliper
    157
  - Assembly
    157
    
    Assembly - Caliper Guide Pin Bushings (Disc/Disc Brakes)
    157
    
    Assembly - Caliper Piston and Seal
    157
    
    Caliper (Disc/Disc Brakes)
    158
    
    Installation
    158
    
    Installation - Front Disc Brake
    158
    
    Installation - Front Disc Brake Caliper (Disc/Drum Brakes)
    159
- Disc Brake Caliper - Rear
  
  159
  - Removal - Rear Disc Brake Caliper
    159
  - Disassembly - Caliper Piston and Seal
    160
  - Cleaning - Caliper
    161
  - Inspection - Caliper
    161
  - Assembly - Caliper Piston and Seal
    161
  - Installation - Rear Disc Brake Caliper
    162
- Disc Brake Caliper Guide Pins
  
  163
  - Removal - Disc Brake Caliper Guide
    163
    
    Pins (Disc/Drum Brakes)
    163
  - Installation - Disc Brake Caliper Guide Pins (Disc/Drum Brakes)
    163
- Disc Brake Caliper Adapter Removal - Front Disc Brake Caliper Adapter
  
  163
  - Installation - Front Disc Brake Caliper Adapter
    163
- Fluid
  
  164
- Drum Removal
  
  164
  - Installation
    164
- Junction Block
  
  165
- Master Cylinder Description Description
  
  166
  - Description - Rhd
    167
  - Operation
    167
  - Standard Procedure - Master Cylinder Bleeding
    167
  - Removal Removal - Lhd
    168
    
    Removal - Rhd
    169
  - Disassembly - Master Cylinder (Fluid Reservoir)
    169
  - Assembly - Master Cylinder (Fluid Reservoir)
    170
  - Installation Installation - Lhd
    170
    
    Installation - Rhd
    171
- Pedal - Adjustable Description
  
  171
  - Operation
    171
  - Diagnosis and Testing - Adjustable Pedal System
    172
  - Removal
    172
  - Installation
    174
- Pedal Torque Shaft - Rhd Removal
  
  176
  - Installation
    176
- Power Brake Booster Description
  
  177
  - Operation
    178
  - Diagnosis and Testing - Power Brake Booster
    178
  - Removal Removal - Lhd
    179
    
    Removal - Rhd
    181
    
    Installation
    182
    
    Installation - Lhd
    182
    
    Installation - Rhd
    184
- Proportioning Valve Description - Proportioning Valve (Height Sensing)
  
  185
- Rotor
  
  188
  - Diagnosis and Testing - Brake Rotor
    188
  - Standard Procedure - Brake Rotor Machining
    190
  - Removal - Front Brake Rotor
    191
  - Installation - Front Brake Rotor
    191
  - Specifications Brake Rotor
    192
    
    Brake Rotor - Export
    192
- Support Plate - Drum Brake Removal
  
  193
  - Installation
    193
- Wheel Cylinders Removal
  
  194
- Cables - Parking Brake Removal Removal - Parking Brake Cable (Front)
  
  196
- Lever - Parking Brake Removal
  
  201
  - Installation
    202
- Cables - Parking Brake (Export)
  
  201
  - Removal - Front Cable
    201
  - Installation - Front Cable
    201
- Lever - Parking Brake (Export)
  
  203
  - Removal - Parking Brake Lever and Front Cable
    203
  - Installation - Parking Brake Lever and Front Cable
    204
- Shoes - Parking Brake Removal
  
  204
  - Installation
    210
  - Adjustments
    212
    
    Adjustment - Parking Brake Shoes
    212
Brakes - Abs

214
- Brakes - Abs
  
  215
  - Description - Electronic Variable
    215
  - Description - Traction Control System
    215
  - Operation
    215
    
    Operation - Antilock Brake System
    215
    
    Operation - Electronic Variable Brake Proportioning
    216
    
    Operation - Traction Control System
    216
  - Caution
    217
    
    Cautions
    217
  - Standard Procedure - Antilock Brake System Bleeding
    217
  - Specifications
    218
    
    Abs Fastener Torque
    218
    
    Tone Wheel Runout
    218
    
    Wheel Speed Sensor Air Gap
    218
- Front Wheel Speed Sensor Removal
  
  218
  - Installation
    218
- Rear Wheel Speed Sensor - Awd Removal
  
  219
- Brakes - Abs
  
  219
  - Installation
    219
- Rear Wheel Speed Sensor - Fwd Removal
  
  220
  - Installation
    220
- Tone Wheel
  
  221
  - Inspection - Tone Wheel
    221
- Traction Control Switch Diagnosis and Testing - Traction Control Switch
  
  221
- Hydraulic/Mechanical
  
  222
  - Operation - Hydraulic Circuits and Valves
    222
- Hcu (Hydraulic Control Unit) Description
  
  228
  - Operation
    228
- Icu (Integrated Control Unit) Description
  
  229
  - Operation
    229
  - Removal Removal - Lhd
    229
    
    Removal - Rhd
    230
  - Disassembly - Icu
    232
  - Assembly - Icu
    232
  - Installation Installation - Lhd
    233
    
    Installation - Rhd
    234
Clutch

236
- Clutch
  
  238
  - Diagnosis and Testing
    238
    
    Diagnosis and Testing - Drive Plate
    240
    
    Misalignment
    240
    
    Diagnosis and Testing - Clutch Chatter Complaints
    241
    
    Diagnosis and Testing - Clutch Cover and Disc Runout
    241
  - Special Tools - T850 Transaxle
    241
- Clutch Release Lever and Bearing
  
  241
  - Removal
    243
- Master Cylinder - Rhd Removal
  
  243
- Clutch
  
  243
  - Installation
    243
- Master Cylinder - Lhd Removal
  
  244
  - Installation
    245
- Modular Clutch Assy - 2.4L Gas Removal
  
  246
  - Installation
    246
- Slave Cylinder Removal
  
  246
- Clutch Disc and Pressure Plate - 2.5L Td Removal
  
  247
  - Installation
    247
- Flywheel Removal
  
  248
  - Installation
    248
Cooling

250
- Cooling
  
  251
  - Diagnosis and Testing Diagnosis and Testing - Cooling System Leak Test
    251
    
    Diagnosis and Testing - Cooling System Flow Check
    252
    
    Diagnosis and Testing - Cooling System Aeration
    253
    
    Diagnosis and Testing - Cooling System Deaeration
    253
- Description
  
  253
Accessory Drive

257
- Drive Belts Description
  
  258
  - Operation
    258
  - Diagnosis and Testing - Accessory Drive Belt
    258
  - Removal
    259
  - Cleaning
    260
  - Inspection
    260
  - Installation
    260
  - Adjustments
    261
  - Drive Belts - 3.3/3.8L Removal
    261
  - Cleaning
    262
  - Inspection
    262
  - Installation
    262
- Belt Tensioner - 3.3/3.8L
  
  258
- Belt Tensioner - 2.4L
  
  258
Rs Engine

263
- Diagnosis and Testing - Engine Cooling System
  264
- Coolant
  
  268
  - Cleaning
    268
  - Diagnosis and Testing - Coolant Concentration Testing
    268
  - Inspection
    268
  - Standard Procedure - Coolant Service
    269
- Coolant Recovery Container Description
  
  269
  - Operation
    269
  - Diagnosis and Testing - Coolant Recovery System
    269
  - Removal
    270
  - Installation
    270
- Engine Block Heater Description
  
  270
  - Operation
    270
  - Diagnosis and Testing - Engine Block Heater Testing
    270
- Engine Coolant Temperature Sensor - 3.3/3.8L Description
  
  271
  - Installation
    271
  - Installation
    272
- Engine Coolant Thermostat Description
  
  272
  - Operation
    272
  - Diagnosis and Testing - Engine Coolant Thermostat
    272
- Engine Coolant Thermostat - 2.4L Removal
  
  272
  - Installation
    273
- Engine Coolant Thermostat - 3.3/3.8L Removal
  
  273
- Radiator
  
  274
  - Description
    274
  - Operation
    274
  - Removal
    276
  - Installation
    276
- Radiator Draincock Removal
  
  276
- Radiator Pressure Cap Description
  
  276
- Radiator Fan Description
  
  278
  - Operation
    278
  - Diagnosis and Testing - Radiator Fan Motor
    279
  - Removal
    279
  - Installation
    280
- Radiator Fan Relay Description
  
  280
  - Operation
    280
  - Removal
    280
  - Installation
    281
- Water Pump - 2.4L Description
  
  281
  - Operation
    281
  - Removal
    281
  - Cleaning
    281
  - Inspection
    281
- Water Pump - 3.3/3.8L Description
  
  283
  - Operation
    283
  - Removal
    283
  - Cleaning
    284
  - Inspection
    284
  - Installation
    284
- Water Pump Inlet Tube - 2.4L Description
  
  285
  - Removal
    285
  - Installation
    285
- Water Pump Inlet Tube - 3.3/3.8L Removal
  
  285
Transmission

287
- Coolers and Tubes
  287
- Cleaning
  288
- Inspection
  288
- Installation
  288
  - Cooling 2.5L Turbo Diesel
    292
  - System
    292
  - Diagnosis and Testing - Cooling System Leak Test
    295
  - Diagnosis and Testing - Cooling System Flow Check
    296
  - Diagnosis and Testing - Cooling System Aeration
    296
  - Cooling 2.5L Turbo Diesel
    296
  - Cleaning
    296
  - Inspection
    296
  - Specifications Specifications - Torque
    297
  - Specifications - Cooling System Capacity
    297
- Transmission Oil Cooler Lines
  288
  - Removal
    288
Accessory Drive

298
- Belt Tensioner
  
  299
  - Removal
    299
  - Installation
    299
- Idler Pulley Removal
  
  299
  - Operation
    299
    
    Operation-Accessory Drive Belt
    299
  - Diagnosis and Testing - Accessory Drive Belt
    300
  - Removal
    300
    
    Removal-Accessory Drive Belt
    300
    
    Installation
    302
    
    Installation-Accessory Drive Belt
    302
    
    Installation-Power Steering Belt
    302
- Drive Belts
  
  299
  - Description
    299
  - Description - Accessory Drive Belt
    299
- Description - Power Steering Belt
  
  299
Rg Engine

303
- Coolant Description
  
  304
  - Diagnosis and Testing - Coolant Concentration Testing
    304
  - Standard Procedure Standard Procedure - Coolant Service
    305
    
    Standard Procedure - Adding Additional Coolant
    305
    
    Standard Procedure - Coolant Level Check
    305
    
    Standard Procedure - Cooling System Filling
    305
    
    Standard Procedure - Cooling System Draining
    306
- Coolant Recovery Press Container Description
  
  306
  - Operation
    306
  - Removal
    307
  - Installation
    307
- Engine Coolant Temp Sensor Description
  
  308
  - Operation
    308
  - Removal
    308
  - Installation
    308
- Engine Coolant Thermostat Description
  
  309
  - Operation
    309
  - Removal
    309
  - Installation
    309
- Radiator Description
  
  310
  - Operation
    310
  - Removal
    310
  - Installation
    311
- Radiator Draincock Removal
  
  311
- Water Pump Description
  
  312
  - Operation
    312
  - Removal
    312
    
    Removal - Water Pump
    312
    
    Removal - Water Pump Housing
    312
  - Cleaning
    312
  - Installation
    312
    
    Installation - Water Pump
    312
    
    Installation - Water Pump Housing
    313
- Radiator Pressure Cap Description
  
  314
  - Operation
    314
  - Diagnosis and Testing Diagnosis and Testing - Cooling System Pressure Cap
    314
    
    Diagnosis and Testing - Pressure Relief Test
    315
  - Cleaning
    315
  - Inspection
    315
- Radiator Fan Description
  
  315
  - Operation
    316
  - Diagnosis and Testing - Radiator Fan Motor
    316
  - Removal
    317
  - Installation
    317
- Hose Clamps
  
  317
  - Description - Hose Clamps
    317
  - Operation - Hose Clamps
    317
- Radiator Fan Relay Description
  
  318
  - Operation
    318
- Coolant System Hoses
  
  318
  - Removal
    318
    
    Removal - Lower Radiator Hose
    318
    
    Removal - Upper Radiator Hose
    318
    
    Removal - Coolant Bypass Hose
    319
  - Installation
    319
    
    Installation - Coolant Bypass Hose
    319
    
    Installation - Lower Radiator Hose
    319
    
    Installation - Upper Radiator Hose
    319
Audio

320
- Antenna Body and Cable Description
  
  323
  - Diagnosis and Testing - Antenna Body and Cable
    323
  - Removal
    323
  - Installation
    324
- Audio
  
  323
  - Description
    323
  - Operation
    323
- Antenna Module - Export Description
  
  325
  - Operation
    325
  - Diagnosis and Testing - Antenna Module - Export
    325
  - Removal
    326
  - Installation
    326
- CD Changer Description
  
  326
  - Operation
    326
- Quarter Glass Integral Antenna - Export Description
  
  327
  - Operation
    327
  - Diagnosis and Testing - Quarter Glass Integral Antenna - Export
    327
- Instrument Panel Antenna Cable Removal
  
  327
  - Installation
    327
- Radio
  
  328
  - Diagnosis and Testing - Radio
    328
  - Removal
    328
  - Installation
    329
- Radio Noise Suppression Components Description
  
  329
  - Operation
    330
- Remote Switches Description
  
  330
  - Diagnosis and Testing - Remote Switches
    330
  - Removal
    331
  - Installation
    331
- Speaker
  
  331
  - Diagnosis and Testing - Speaker
    331
  - Removal
    332
Chime/Buzzer

334
Electronic Control Modules

338
- Electronic Control Modules Standard Procedure - Pcm/Skim Programming
  339
- Body Control Module Description
  
  340
  - Operation
    340
  - Removal
    342
  - Installation
    342
- Adjustable Pedal Module
  
  340
  - Diagnosis and Testing - Adjustable
    340
  - Pedal Module
    340
  - Removal
    340
  - Installation
    340
- Electronic Control Modules
  
  340
- Controller Antilock Brake Description
  
  342
  - Removal
    343
  - Installation
    343
- Front Control Module
  
  345
  - Diagnosis and Testing - Front Control Module
    345
  - Removal
    345
  - Installation
    345
- Data Link Connector
  
  346
- Heated Seat Module Description
  
  346
  - Operation
    346
  - Diagnosis and Testing - Heated Seat Module
    346
  - Removal
    347
  - Installation
    347
- Power Liftgate Module Description
  
  347
  - Operation
    347
  - Installation
    348
- Powertrain Control Module Description Description
  
  348
  - Diagnostic Trouble Code
    350
  - Operation - Sensor Return - Pcm Input
    362
  - Operation - Sci Receive - Pcm Input
    362
  - Operation - Ignition Sense - Pcm Input
    362
  - Operation - Pcm Ground
    362
  - Operation
    362
    
    Operation - 5 Volt Supply - Pcm Output
    362
    
    Operation - 8-Volt Supply - Pcm Output
    362
    
    Standard Procedure - Obtaining Diagnostic Trouble Codes
    362
  - Removal
    363
  - Installation
    363
- Sentry Key Immobilizer Module Description
  
  363
  - Operation
    364
  - Removal
    364
  - Installation
    364
- Transmission Control Module Description
  
  365
  - Operation
    365
  - Standard Procedure Standard Procedure - Pinion Factor Setting
    368
    
    Standard Procedure - Quick Learn Procedure
    368
  - Removal
    368
  - Installation
    369
- Sliding Door Control Module Description
  
  370
  - Operation
    371
  - Removal
    371
  - Installation
    371
- Memory Seat/Mirror Module Description
  
  370
  - Operation
    370
  - Diagnosis and Testing - Memory Seat/Mirror Module
    370
  - Removal
    370
  - Installation
    370
Engine Systems

376
- Battery System
  
  377
  - System
    379
  - Cleaning
    380
  - Inspection
    380
  - Specifications
    381
  - Special Tools
    382
    
    Battery System Special Tools
    382
  - Description
    382
  - Operation
    384
  - Standard Procedure Standard Procedure - Spiral Plate Battery Charging
    385
    
    Standard Procedure - Conventional Battery Charging
    386
    
    Standard Procedure - Ignition-Off Draw Test
    388
    
    Standard Procedure - Open-Circuit Voltage Test
    388
    
    Standard Procedure - Checking Battery Electrolyte Level
    389
- Battery System
  
  389
  - Removal - Battery
    389
  - Installation
    390
- Battery Holddown Description
  
  390
  - Operation
    390
  - Removal
    390
  - Installation
    391
- Battery Cables Description
  
  391
  - Operation
    391
  - Diagnosis and Testing - Battery Cable
    391
  - Removal
    393
  - Installation
    393
- Battery Tray Description
  
  393
  - Operation
    394
  - Removal
    394
  - Installation
    394
- Thermowrap
  
  394
  - Description
    394
  - Operation
    395
  - Removal
    395
  - Installation
    395
Charging

396
- Charging
  
  397
  - Diagnosis and Testing - On-Board
    397
    
    Diagnostic System
    397
  - Specifications
    398
    
    Generator
    398
    
    Torque
    398
  - Special Tools
    398
- Battery Temperature Sensor
  
  399
  - Description
    399
  - Operation
    399
  - Removal
    399
- Generator Description
  
  399
  - Removal Removal - 2.4L
    399
    
    Removal - 3.3/3.8L
    399
  - Installation Installation - 2.4L
    400
    
    Installation - 3.3/3.8L
    400
- Generator Decoupler Pulley Description
  
  400
  - Operation
    401
  - Diagnosis and Testing - Generator Decoupler Pulley
    401
  - Removal
    401
  - Installation
    401
- Voltage Regulator Description
  
  402
  - Operation
    402
Starting

403
- Circuit Test
  406
- Starting
  
  408
  - Diagnosis and Testing - Feed Circuit
    408
    
    Resistance Test
    408
  - Diagnosis and Testing - Feed Circuit Test
    408
  - Starter
    409
  - Torques
    409
  - Removal
    410
    
    Removal - 2.4L
    410
    
    Removal - 3.3/3.8L
    411
- Starter Motor
  
  410
  - Installation
    411
    
    Installation - 2.4L
    411
    
    Installation - 3.3/3.8L
    411
Engine Systems

412
- Battery System
  
  413
- Battery System
  
  414
  - Inspection
    417
  - Specifications
    417
    
    Battery System Special Tools
    418
- Battery Description
  
  418
- Battery System
  
  425
- Battery Holddown Description
  
  426
  - Operation
    426
  - Removal
    427
  - Installation
    427
- Battery System
  
  426
  - Removal - Battery
    426
  - Installation
    426
- Battery Cables Description
  
  427
  - Operation
    427
  - Diagnosis and Testing - Battery Cable
    427
  - Removal
    429
  - Installation
    429
- Battery Tray Description
  
  429
  - Operation
    430
  - Removal
    430
  - Installation
    430
- Thermowrap
  
  430
  - Description
    430
Charging

431
- Diagnosis and Testing - On-Board Diagnostic System
  432
- Special Tools
  433
- Specifications
  433
  - Generator
    433
  - Torque
    433
- Generator Description
  
  434
  - Removal - 2.4L
    434
- Battery Temperature Sensor
  
  434
  - Description
    434
  - Operation
    434
  - Removal
    434
- Charging
  
  434
  - Removal - 2.5L
    435
  - Removal - 3.3/3.8L
    436
  - Removal - 3.5L
    437
  - Installation
    438
    
    Installation - 2.4L
    438
    
    Installation - 2.5L
    439
    
    Installation - 3.3/3.8L
    439
    
    Installation - 3.5L
    439
- Generator Decoupler Pulley
  
  439
  - Description
    441
  - Operation
    441
  - Installation
    441
- Voltage Regulator Description
  
  441
Starting

442
- Starting
  
  445
  - Diagnosis and Testing - Control
    445
    
    Circuit Test
    445
  - Diagnosis and Testing - Feed Circuit
    447
    
    Resistance Test
    447
  - Diagnosis and Testing - Feed Circuit Test
    447
- Starting
  
  447
- Starter Motor Removal Removal - 2.4L
  
  449
  - Removal - 3.3/3.8L
    450
  - Removal - 3.5L
    450
  - Removal - 2.5L
    451
  - Installation
    452
  - Installation - 2.4L
    452
  - Installation - 2.5L
    452
  - Installation - 3.3/3.8L
    452
  - Installation - 3.5L
    452
Heated Systems

454
- Heated Glass
  455
Heated Mirrors

458
- Heated Mirrors Description
  458
  - Operation
    459
- Heated Mirrors
  459
  - Heated Mirror Grid
    459
    
    Standard Procedure - Heated Mirror
    459
  - Mirror Switch
    459
    
    Description
    459
  - Relay Description
    459
    
    Diagnosis and Testing - Heated Seat
    461
    
    Heated Seat System
    461
    
    Operation
    461
    
    System
    461
    
    Diagnosis and Testing - Driver Heated Seat Switch
    462
    
    Driver Heated Seat Switch
    462
    
    Operation
    462
    
    Installation
    463
    
    Removal
    463
    
    Diagnosis and Testing - Heated Seat Elements
    464
    
    Heated Seat Element Description
    464
    
    Heated Seat System
    464
    
    Operation
    464
    
    Diagnosis and Testing - Heated Seat Sensor
    465
    
    Heated Seat Sensor Description
    465
    
    Installation
    465
    
    Operation
    465
    
    Removal
    465
    
    Diagnosis and Testing - Passenger Heated Seat Switch
    466
    
    Operation
    466
    
    Passenger Heated Seat Switch Description
    466
    
    Removal
    467
    
    Installation
    468
Ignition Control

476
- Specifications
  477
  - Spark Plug
    477
  - Spark Plug Cable Resistance
    477
  - Torque
    477
  - Firing Order
    478
- Camshaft Position Sensor Description
  
  478
  - Operation
    479
  - Removal Removal - 2.4L
    479
    
    Removal - 3.3/3.8L
    479
  - Installation Installation - 2.4L
    481
    
    Installation - 3.3/3.8L
    481
- Auto Shut down Relay
  
  478
  - Description
    478
  - Operation
    478
- Ignition Coil Description
  
  481
  - Operation
    481
  - Removal Removal - 2.4L
    482
- Ignition Control
  
  482
  - Removal - 3.3/3.8L
    482
  - Installation Installation - 2.4L
    482
    
    Installation - 3.3/3.8L
    483
- Knock Sensor Description
  
  483
  - Operation
    483
  - Removal Removal - 2.4L
    483
    
    Installation - 3.8L
    483
    
    Installation Installation - 2.4L
    483
    
    Removal - 3.8L
    483
- Spark Plug
  
  484
  - Description
    484
    
    Description - Platinum Plugs
    484
    
    Description - Standard 4 Cylinder
    484
  - Removal
    484
  - Installation
    485
- Spark Plug Cable Description
  
  485
  - Removal
    485
Ignition Control

486
- Camshaft Position Sensor Description
  
  487
  - Removal
    487
  - Installation
    487
- Glow Plug
  
  487
  - Description
    487
  - Operation
    487
Table of Contents

502
- Operation
  504
- Warning
  504
- Description
  505
- Operation
  505
- Specifications
  505
- Switch
  505
- Removal
  506
- Center High Mounted Stop Lamp Unit
  
  507
  - Installation
    507
- Center High Mounted Stop Lamp
  
  507
  - Removal
    507
- Fog Lamp
  
  508
  - Diagnosis and Testing - Fog Lamp
    508
  - Removal
    510
  - Installation
    510
- Fog Lamp - Export Removal
  
  510
- Fog Lamp Unit Standard Procedure Standard Procedure - Fog Lamp Unit Alignment
  
  511
  - Standard Procedure - Fog Lamp Unit Alignment - Export
    511
  - Removal
    512
  - Installation
    512
- Lamps/Lighting - Interior
  
  512
- Front Position Lamp - Export Removal
  
  512
- Headlamp
  
  513
  - Diagnosis and Testing - Headlamp
    513
  - Removal
    515
  - Installation
    515
- Lamps/Lighting - Exterior
  
  513
- Headlamp - Export Removal
  
  515
- Headlamp Leveling Motor - Export
  
  516
  - Leveling Motor - Export
    516
  - Removal
    516
  - Installation
    516
- Headlamp Switch Diagnosis and Testing Diagnosis and Testing - Headlamp Switch
  
  517
  - Diagnosis and Testing - Headlamp Switch - Export
    518
- Headlamp Leveling Switch - Export Description
  
  517
  - Diagnosis and Testing - Headlamp Leveling Switch - Export
    517
- Headlamp Unit Standard Procedure Standard Procedure - Headlamp Unit Alignment
  
  518
  - Standard Procedure - Headlamp Unit Alignment - Export
    520
  - Removal
    520
  - Installation
    521
- Multi-Function Switch
  
  522
  - Description - Turn Signal System
    522
  - Operation - Turn Signal System
    522
  - Diagnosis and Testing - Multi-Function Switch
    523
  - Removal
    523
  - Installation
    523
- License Lamp Removal
  
  522
  - Installation
    522
- Park/Turn Signal Lamp Removal
  
  523
- Park/Turn Signal Lamp - Export Removal
  
  523
  - Installation
    524
- Lamps/Lighting - Exterior Description
  
  524
- Tail Lamp - Export Removal
  
  524
  - Installation
    525
- Rear Fog Lamp - Export Description
  
  524
- Repeater Lamp - Export Removal
  
  524
- Tail Lamp Removal
  
  524
- Tail Lamp Unit Removal
  
  525
Lamps/Lighting - Interior

526
- Dome Lamp
  
  527
- Lamps/Lighting - Interior
  
  527
  - Center Console Lamp Switch Removal
    527
    
    Installation
    527
  - Cluster Illumination Lamps Removal
    527
  - Courtesy Lamp Removal
    527
  - Dome Lamp Removal
    527
  - Glove Box Lamp Switch Removal
    527
    
    Installation
    528
  - Liftgate Lamp Removal
    528
  - Reading Lamp Removal
    528
    
    Installation
    529
  - Vanity Lamp Removal
    529
Message Systems

530
- Overhead Console
  
  531
  - Operation
    531
  - Diagnosis and Testing - Overhead
    531
    
    Console
    531
  - Standard Procedure
    532
    
    Courtesy Lamp Replacement
    532
    
    Standard Procedure - Compass Calibration
    532
    
    Standard Procedure - Reading
    532
    
    Standard Procedure - Compass Demagnetizing
    533
    
    Standard Procedure - Compass Variation Adjustment
    533
  - Removal - Overhead Console
    534
  - Installation
    534
- Electronic Vehicle Info Center Description
  
  535
- Universal Transmitter Description
  
  538
  - Operation
    539
  - Diagnosis and Testing - Universal Transmitter
    539
- Compass/Mini-Trip Computer Description
  
  538
  - Operation
    538
  - Diagnosis and Testing - Compass Mini-Trip Computer
    538
  - Removal
    538
  - Installation
    538
- Ambient Temp Sensor Description
  
  539
Power Systems

542
- Power Liftgate System
  
  543
- Pinch Sensor Description
  
  550
  - Operation
    550
  - Removal
    550
  - Installation
    550
- Full Open Switch Description
  
  551
  - Operation
    551
  - Removal
    551
  - Installation
    551
- Liftgate Motor Description
  
  551
  - Operation
    552
  - Removal
    552
  - Installation
    552
- Engage Actuator Description
  
  552
  - Removal
    553
  - Installation
    553
- Power Liftgate System
  
  553
- Transverse Bracket
  
  554
  - Description
    555
  - Operation
    555
  - Removal
    555
  - Installation
    555
- Lift Gear & Link Rod
  
  555
  - Description
    556
  - Operation
    556
  - Removal
    556
  - Installation
    556
- Latch Actuator
  
  556
  - Operation
    557
  - Removal
    557
  - Installation
    557
- Exterior Handle Switch
  
  558
  - Operation
    558
  - Removal
    558
  - Installation
    558
- Chime/Thermistor Description
  
  558
Power Sliding Door System

559
- Diagnosis and Testing - Power Sliding
  562
  - Standard Procedure - Power Door
    568
  - Standard Procedure - Sliding Door
    568
- Power Sliding Door System
  562
- Latch
  
  569
  - Description
    569
  - Operation
    569
  - Removal
    569
  - Installation
    570
  - Operation
    570
  - Removal
    570
  - Installation
    571
- Sliding Door Motor
  
  570
- Full Open Switch
  
  571
  - Description
    572
- Power Sliding Door System
  
  572
- Lower Drive Unit Description
  
  572
  - Removal
    573
  - Installation
    573
- Left B-Pillar Switch
  
  572
  - Operation
    572
  - Removal
    572
  - Installation
    572
- Right B-Pillar Switch Description
  
  572
- Lower Drive Unit Track & Rack Description
  
  574
  - Operation
    574
  - Removal
    574
  - Installation
    574
- Wiring Harness
  
  575
  - Description
    575
  - Operation
    575
  - Removal
    575
  - Installation
    576
- Flex Drive
  
  576
  - Description
    576
  - Operation
    577
  - Removal
    577
  - Installation
    577
- Sliding Door Module
  
  578
  - Description
    578
  - Operation
    578
  - Removal
    579
  - Installation
    579
Power Locks

580
- Power Locks
  
  581
  - Operation
    581
- Door Cylinder Lock Switch
  
  582
  - Operation
    582
  - Diagnosis and Testing - Door Cylinder Lock Switch
    582
  - Removal
    583
  - Installation
    583
- Door Lock Motor Diagnosis and Testing - Door Lock Motor
  
  583
- Door Lock Switch Diagnosis and Testing - Door Lock Switch
  
  583
  - Removal
    584
  - Installation
    584
  - Keyless Entry Transmitter Standard Procedure Standard Procedure - Horn Chirp Preference
    584
    
    Standard Procedure - Battery Replacement
    584
  - Specifications
    584
    
    Battery
    584
    
    Range
    584
- Remote Keyless Entry Module Description
  
  585
  - Operation
    585
  - Diagnosis and Testing - Remote Keyless Entry Module
    585
    
    Standard Procedure - Programming Rke Module
    585
  - Removal
    585
  - Installation
    586
- Sliding Door Lock Motor Removal
  
  586
Power Mirrors

587
- Automatic Day / Night Mirror
  589
- Diagnosis and Testing - Automatic Day
  589
- Power Mirrors
  589
- Power Foldaway Mirror Switch - Export Description
  590
- Remote Switch
  590
- Sideview Mirror Removal
  590
- Switch
  590
  - Removal
    590
  - Installation
    590
Power Seat System

592
- Power Seat System
  
  593
- Driver Seat Switch Description
  
  595
  - Diagnosis and Testing - Driver Seat
    596
    
    Switch
    596
  - Installation
    597
- Memory Set Switch Description
  
  597
  - Operation
    597
  - Diagnosis and Testing - Memory Switch
    598
  - Removal
    598
  - Installation
    598
- Passenger Seat Switch Description
  
  598
  - Operation
    598
  - Installation
    600
- Memory Mirror/Seat Module Description
  
  600
  - Operation
    600
  - Diagnosis and Testing - Memory Mirror/Seat Module
    600
  - Removal
    600
- Driver Power Seat Track Description
  
  601
  - Operation
    601
  - Diagnosis and Testing - Driver Power Seat Track
    601
  - Removal
    602
  - Installation
    602
- Passenger Power Seat Track Description
  
  602
  - Operation
    603
  - Diagnosis and Testing - Power Seat Track
    603
  - Removal
    603
Restraints

610
- Restraints
  
  611
  - Restraints Description
    611
  - Operation
    611
  - Warning
    611
  - Diagnosis and Testing - Airbag System
    611
- Driver Airbag Description
  
  612
  - Standard Procedure - Clean up
    613
  - Removal
    613
  - Installation
    613
- Clock Spring Description
  
  612
  - Operation
    612
  - Standard Procedure - Clock Spring Centering
    612
  - Removal
    612
  - Installation
    612
- Driver Airbag Trim Cover Removal
  
  613
  - Installation
    614
- Occupant Restraint Controller Description
  
  614
  - Operation
    614
  - Removal
    614
- Passenger Airbag Description
  
  615
  - Operation
    615
  - Standard Procedure - Clean up
    615
  - Removal
    615
  - Installation
    615
- Seat Belt Outboard Front Removal
  
  616
  - Installation
    616
- Seat Airbag Description
  
  616
  - Operation
    616
- Seat Belt First Row Anchor Bracket - Lwb Removal
  
  617
  - Installation
    617
- Seat Belt Left First Row Outboard - Swb Three Door Removal
  
  617
- Seat Belt First Row Outboard - Swb Four Door Removal
  
  618
  - Installation
    618
- Seat Belt First Row Outboard - Lwb Four Door Removal
  
  619
  - Installation
    619
- Seat Belt Second Right Row Outboard - Lwb Removal
  
  619
- Seat Belt Second Right Row Outboard - Lbw with Rear Hvac Removal
  
  620
  - Installation
    620
- Seat Belt Second Row Outboard - Swb Removal
  
  621
  - Installation
    621
- Seat Belt Buckle First Row Quad Bucket Removal
  
  622
- Seat Belt Buckle - Front Inboard Removal
  
  622
  - Installation
    622
- Seat Belt Tensioner Description
  
  623
  - Operation
    623
- Seat Belt Buckle Second Row - Three Passenger Bench Removal
  
  623
- Seat Belt Buckle First Row - Two Passenger Bench Removal
  
  623
  - Installation
    623
- Shoulder Belt Height Adjuster Removal
  
  624
  - Installation
    624
- Shoulder Belt Height Adjuster Knob Removal
  
  624
- Side Impact Airbag Control Module Description
  
  625
  - Operation
    625
  - Removal
    625
  - Installation
    625
Speed Control

626
- Speed Control
  
  627
  - Operation
    627
  - Diagnosis and Testing - Road Test
    628
  - Specifications - Torque
    628
- Cable Description
  
  629
  - Operation
    629
  - Removal
    629
  - Installation
    629
  - Description
    629
- Speed Control
  
  629
  - Installation
    630
- Switch Description
  
  630
  - Operation
    630
  - Removal
    630
  - Installation
    631
- Vacuum Reservoir Description
  
  631
  - Operation
    631
  - Removal
    631
Wipers/Washers

638
- Wipers/Washers
  
  639
  - Operation
    639
  - Diagnosis and Testing
    639
    
    Diagnosis and Testing - Front Wiper
    639
    
    Diagnosis and Testing - Front Wiper/Washer Switch
    639
    
    System
    639
    
    Diagnosis and Testing - Failed Park Switch
    640
    
    Diagnosis and Testing - Rear Wiper System
    642
    
    Diagnosis and Testing - Washer System
    642
- Front Wiper Arms Standard Procedure - Front Wiper Arm Alignment
  
  646
  - Removal
    647
  - Installation
    647
- Front Washer Pump Motor Removal
  
  646
  - Installation
    646
- Front Wiper Motor Removal
  
  647
- Headlamp Washers - Export Description
  
  648
  - Operation
    648
  - Diagnosis and Testing - Headlamp Washers - Export
    648
  - Removal
    650
  - Installation
    650
- Headlamp Washer Pump Motor - Export Removal
  
  650
  - Installation
    651
- Wipers/Washers
  
  650
- Headlamp Washer Hose - Export Removal
  
  650
- Rear Washer Pump Motor Removal
  
  651
  - Installation
    652
- Rear Wiper Arm Removal
  
  652
- Rear Wiper/Washer Switch Description
  
  653
  - Operation
    653
- Rear Wiper Motor Removal
  
  653
  - Installation
    653
- Washer Fluid Level Switch Removal
  
  653
  - Installation
    654
- Washer Hoses Removal
  
  654
- Wiper Blades Removal
  
  655
  - Cleaning
    656
  - Installation
    656
- Washer Reservoir Removal
  
  655
  - Installation
    655
- Wiper Linkage Removal
  
  656
- Wiper Module Removal
  
  656
  - Installation
    657
Wiring Diagram

660
- Wiring Diagram Information
  
  660
- Connector Removal
  
  670
  - Installation
    670
- Diode Removal
  
  673
  - Installation
    673
    
    Terminal Removal
    673
- Terminal
  
  674
- Wire
  
  674
  - Standard Procedure - Wire Splicing
    674

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Chrysler Dodge Caravan 2002 Manual (2399 pages)

Table of Contents

Lubrication & Maintenance

International Symbols

Lubrication & Maintenance

Hoisting

Description - Engine Oil - Diesel Engines

Lubrication & Maintenance

Fluid Fill/Check Locations Description

Lubrication Points Description

Maintenance Schedules Description

Jump Starting

Towing

Suspension

Front Suspension

Bushings

Hub / Bearing Description

Knuckle Description

Lower Ball Joint Description

Lower Ball Joint Seal Boot

Front Suspension

Lower Control Arm Description

Stabilizer Bar

Strut

Rear Suspension

Bushings

Hub / Bearing Description

Jounce Bumper Description

Rear Suspension

Shock Absorber Description

Spring - Awd Description

Spring - Fwd Description

Spring Mounts - Front Removal

Spring Mounts - Rear Removal

Stabilizer Bar Description

Track Bar Description

Differential & Driveline

Half Shaft - Front Description

Half Shaft - Front

CV Boot - Inner

Half Shaft - Front

CV Boot - Outer Removal

Outer CV Joint Bearing Shield Removal

Rear Driveline Module

Rear Driveline Module Description

Bi-Directional Overrunning Clutch Description

Differential Assembly Description

Fluid - Differential Assembly

Fluid

Viscous Coupler Description

Torque Arm Removal

Input Flange Seal Removal

Output Flange Seal Removal

Brakes

Brakes - Base

Brake Fluid Level Switch

Adjustable Pedal Switch

Pedal Position Sensor Description

Hydraulic/Mechanical

Brakes - Base

Brake Pads/Shoes - Front

Brake Lines

Brake Pads/Shoes - Rear Disc

Brake Pads/Shoes - Rear Drum

Disc Brake Caliper - Front

Disc Brake Caliper - Rear

Disc Brake Caliper Guide Pins

Disc Brake Caliper Adapter Removal - Front Disc Brake Caliper Adapter

Fluid

Drum Removal

Junction Block

Master Cylinder Description Description

Pedal - Adjustable Description

Pedal Torque Shaft - Rhd Removal

Power Brake Booster Description

Proportioning Valve Description - Proportioning Valve (Height Sensing)

Rotor

Support Plate - Drum Brake Removal

Wheel Cylinders Removal