Chrysler Dodge Caravan 2002 User manual

GROUP TAB LOCATOR
IN
Introduction
0
Lubrication & Maintenance
2
Suspension
3
Differential & Driveline
5
Brakes
6
Clutch
7
Cooling
7a
Cooling - 2.5L Turbo Diesel
8A
Audio
8B
Chime/Buzzer
8E
Electronic Control Modules
8Ea
Electronic Control Modules
8F
Engine Systems
8Fa
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8Ia
Ignition Control
8J
Instrument Cluster
8L
Lamps
8M
Message Systems
8N
Power Systems
8O
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8W
Wiring
9
Engine
9a
Engine
11
Exhaust System
11a
Exhaust System and Turbocharger
13
Frame & Bumpers
14
Fuel System
14a
Fuel System
19
Steering
21
Transmission
22
Tires/Wheels
23
Body
24
Heating & Air Conditioning
25
Emissions Control
25a
Emissions Control 2.5L Turbo Diesel
Service Manual Comment Forms

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION ..........................1
FASTENER IDENTIFICATION
DESCRIPTION ..........................2
FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE ........5
DESCRIPTION - THREADED HOLE REPAIR . . 5
INTERNATIONAL SYMBOLS
DESCRIPTION ..........................5
METRIC SYSTEM
DESCRIPTION ..........................6
TORQUE REFERENCES
DESCRIPTION ..........................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION ..........................9
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION .........................11
E-MARK LABEL
DESCRIPTION .........................11
VECI LABEL
DESCRIPTION .........................11
MANUFACTURER PLATE
DESCRIPTION .........................11
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
BODY CODE PLATE – LINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13 THROUGH 17
Open Space
DIGITS 18 AND 19
Vehicle Shell Line
•RS
DIGIT 20
Carline
FWD
•K = Dodge
•Y = Chrysler
AWD
•C = Chrysler
•D = Dodge
Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
8 - TRIM
9 - TRANSMISSION
10 - MARKET
11 - VIN
RS INTRODUCTION 1

DIGIT 21
Price Class
•H = Highline
•L = Lowline
•P = Premium
•S = Luxury
•X = Premium
DIGITS 22 AND 23
Body Type
•52 = Short Wheel Base
•53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary Paint (Refer to 23 - BODY/PAINT - SPEC-
IFICATIONS).
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
•EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline
(MPI)
•EGA = 3.3L 6 cyl. Gasoline (SMPI)
•EGH = 3.8L 6 cyl. Gasoline (SMPI)
•EGM = 3.3L 6 cyl. Ethanol Flexible Fuel
•ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
•DGC = 31TH 3-Speed Automatic Transaxle
•DGL = 41AE/TE 4-Speed Electronic Automatic
•DDR = T850 5-Speed Manual Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
•C = Canada
•B = International
•M = Mexico
•U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
•Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
2 INTRODUCTION RS
BODY CODE PLATE (Continued)

Fig. 2 FASTENER IDENTIFICATION
RS INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH
4 INTRODUCTION RS
FASTENER IDENTIFICATION (Continued)

FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RS INTRODUCTION 5

METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.) (Fig. 5).
6 INTRODUCTION RS

Fig. 5 METRIC CONVERSION CHART
RS INTRODUCTION 7
METRIC SYSTEM (Continued)

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
tions Chart for torque references not listed in the
individual torque charts (Fig. 6).
Fig. 6 TORQUE SPECIFICATIONS
8 INTRODUCTION RS

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel, near the left windshield
pillar (Fig. 7). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the vehicle iden-
tification number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Built in the United States by DaimlerChrysler
2 = Built in Canada by DaimlerChrysler Canada Inc.
2 Make B = Dodge
C = Chrysler
3 Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags
8 = Multipurpose Pass. Vehicle With Side Air Bags
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.)
5 Car Line P = Chrysler, Town & Country - FWD
P = Dodge, Caravan/Grand Caravan - FWD
T = Chrysler, Town & Country - AWD
T = Dodge, Grand Caravan - AWD
J = Chrysler, Voyager/Grand Voyager - FWD
Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Left Hand Drive
Fig. 7 VEHICLE IDENTIFICATION NUMBER (VIN)
1 - DEFROSTER OUTLET
2 - VEHICLE IDENTIFICATION NUMBER
3 - HEATED WINDSHIELD GRID
RS INTRODUCTION 9