Chryser Town & Country Dodge Caravan Voyager Gas & Diesel Service Repair Workshop Manual 2001-2007

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🏷️ Basic Information Identification Make: Chrysler/Dodge/Plymouth Model: Town & Country, Caravan, Voyager Generation: Fourth Generation (RS) Production Years Covered: 2001-2007 Codes Platform Code: RS 👋 Introduction Market Position Segment: Minivan Target Audience: DIY Mechanics, Professional Technicians, Fleet Maintenance Competitive Analysis Competitors: Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Uplander/Venture/Montana Key Features Vehicle Strengths: Spacious interior, flexible seating configurations, Stow 'n Go seating (on select trims), comfortable ride, accessible pricing. Manual Benefits: Empowers owners to perform maintenance and repairs, saving money and extending vehicle life. Provides expert-level diagnostic information. 📋 Manual Details Coverage Areas Regions Covered: North America (USA, Canada, Mexico) Page Count Estimated Page Count: 1500+ Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Digital Format: Downloadable (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L V6, 3.8L V6, 4.0L V6), Transmission (4-speed Automatic - 41TE/42LE/45RFE), Drivetrain Chassis: Suspension (Front/Rear), Steering, Brakes (ABS, Power Assist), Wheels and Tires Electrical: Ignition System, Charging System, Starting System, Lighting, Instrumentation, HVAC Controls, Power Accessories (Doors, Windows, Seats), Audio System, Body Control Modules (BCM), Powertrain Control Modules (PCM) Body And Interior: Body Panels, Doors, Hood, Liftgate, Interior Trim, Seats, Restraint Systems (Airbags, Seatbelts) Procedures Included Maintenance: Oil Change, Filter Replacement, Fluid Checks and Top-offs, Belt Inspection/Replacement, Spark Plug Replacement, Air Filter Replacement Diagnostics And Troubleshooting: Diagnostic Trouble Codes (DTCs), Engine Performance Issues, Transmission Slipping, Electrical Faults, HVAC Malfunctions, Brake System Problems Repair And Rebuild: Engine Component Replacement (e.g., heads, pistons), Transmission Overhaul, Suspension Component Replacement, Brake Caliper/Rotor Replacement, Electrical Component Diagnosis and Replacement, Body Panel Repair Special Procedures: PCM/BCM Reprogramming, Key Fob Programming, Airbag System Service, ABS Bleeding, HVAC System Evacuation and Recharge (R134a/R1234yf if applicable for later models) Technical Depth Depth: Comprehensive; covers basic maintenance to full engine and transmission rebuilds. Includes wiring diagrams, diagnostic procedures, and specifications. 📊 Manual Specifications File Format File Quality: High-resolution, searchable PDF with selectable text and clear diagrams. Print Compatibility: Printable on standard home or office printers. Sections can be printed as needed. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 3.3L V6 OHV (EGA) Engine 1 Displacement: 3301 cc (201.5 ci) Engine 1 Bore X Stroke: 96.0 mm x 76.0 mm (3.78 in x 3.00 in) Engine 1 Compression Ratio: 9.0:1 Engine 1 Horsepower Approx: 180-185 hp @ 5000-5200 rpm Engine 1 Torque Approx: 200-205 lb-ft @ 3400-4000 rpm Secondary Engine Engine 2: 3.8L V6 OHV (L32) Engine 2 Displacement: 3778 cc (230.5 ci) Engine 2 Bore X Stroke: 96.0 mm x 87.0 mm (3.78 in x 3.43 in) Engine 2 Compression Ratio: 8.4:1 Engine 2 Horsepower Approx: 200-215 hp @ 5000-5200 rpm Engine 2 Torque Approx: 230-235 lb-ft @ 3000-4000 rpm Tertiary Engine Engine 3: 4.0L V6 SOHC (ЕНК) Engine 3 Displacement: 3952 cc (241.2 ci) Engine 3 Bore X Stroke: 96.0 mm x 90.9 mm (3.78 in x 3.58 in) Engine 3 Compression Ratio: 9.1:1 Engine 3 Horsepower Approx: 240-250 hp @ 5800-6000 rpm Engine 3 Torque Approx: 250-260 lb-ft @ 4000-4400 rpm Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline (87 octane recommended) Fuel Pump: In-tank Electric 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transaxle Transmission Codes Common: 41TE, 42LE, 45RFE (depending on engine and year) Optional Optional Transmission: None (All models were automatic) Features Transmission Features: Electronically controlled, torque converter lock-up, selectable gear ranges (OD, 3, 2, 1). Fluid Specifications Transmission Fluid Type: ATF+4 (Chrysler Material Standard MS-9602) Fluid Capacities Transmission Fluid Capacity Approx: 4.5-5.5 quarts (4.3-5.2 liters) - dry fill 📐 Dimensions Exterior Length Overall Approx: 199.5 - 200.5 inches (5067 - 5093 mm) Width Without Mirrors Approx: 76.0 - 76.5 inches (1930 - 1943 mm) Height Overall Approx: 68.0 - 69.0 inches (1727 - 1753 mm) Wheelbase Approx: 119.2 inches (3028 mm) Interior Passenger Volume Approx: 140-160 cu ft (3964 - 4531 liters) Cargo Cargo Volume Behind 3Rd Row Approx: 30-40 cu ft (850 - 1132 liters) Cargo Volume Behind 2Nd Row Approx: 75-90 cu ft (2124 - 2549 liters) Cargo Volume Max Approx: 140-160 cu ft (3964 - 4531 liters) Weights Curb Weight Approx: 4100 - 4500 lbs (1860 - 2041 kg) Gross Vehicle Weight Rating Gvwr Approx: 5700 - 6000 lbs (2585 - 2722 kg) 🛡️ Safety Features Ratings NHTSA Front Driver Side Impact Rating: 5 Stars (for most models in this range) NHTSA Front Passenger Side Impact Rating: 5 Stars (for most models in this range) NHTSA Side Driver Front Seat Rating: 4-5 Stars (depending on side airbags) NHTSA Side Rear Passenger Rating: 4-5 Stars (depending on side airbags) IIHS Moderate Overlap Front Rating: Good (for most models in this range) IIHS Side Impact Rating: Good or Acceptable (depending on equipment) Active Features ABS: Standard Traction Control: Optional on some trims, standard on later models Electronic Stability...

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Typ: Caravan Voyager

Anbieter:

Art.-Nr: 213993

Sammlungen: ALL Chrysler

Verfügbarkeit: Auf Lager

Stichworte: 2001 2002 2003 2004 2005 2006 2007 Caravan Caravan Voyager Cars Chrysler Dodge Misc Voyager

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Chrysler/Dodge/Plymouth

Model:

Town & Country, Caravan, Voyager

Generation:

Fourth Generation (RS)

Production Years Covered:

2001-2007

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

DIY Mechanics, Professional Technicians, Fleet Maintenance

Competitive Analysis

Competitors:

Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Uplander/Venture/Montana

Key Features

Vehicle Strengths:

Spacious interior, flexible seating configurations, Stow 'n Go seating (on select trims), comfortable ride, accessible pricing.

Manual Benefits:

Empowers owners to perform maintenance and repairs, saving money and extending vehicle life. Provides expert-level diagnostic information.

📋 Manual Details

Coverage Areas

Regions Covered:

North America (USA, Canada, Mexico)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Digital Format:

Downloadable (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (3.3L V6, 3.8L V6, 4.0L V6), Transmission (4-speed Automatic - 41TE/42LE/45RFE), Drivetrain

Chassis:

Suspension (Front/Rear), Steering, Brakes (ABS, Power Assist), Wheels and Tires

Electrical:

Ignition System, Charging System, Starting System, Lighting, Instrumentation, HVAC Controls, Power Accessories (Doors, Windows, Seats), Audio System, Body Control Modules (BCM), Powertrain Control Modules (PCM)

Body And Interior:

Body Panels, Doors, Hood, Liftgate, Interior Trim, Seats, Restraint Systems (Airbags, Seatbelts)

Procedures Included

Maintenance:

Oil Change, Filter Replacement, Fluid Checks and Top-offs, Belt Inspection/Replacement, Spark Plug Replacement, Air Filter Replacement

Diagnostics And Troubleshooting:

Diagnostic Trouble Codes (DTCs), Engine Performance Issues, Transmission Slipping, Electrical Faults, HVAC Malfunctions, Brake System Problems

Repair And Rebuild:

Engine Component Replacement (e.g., heads, pistons), Transmission Overhaul, Suspension Component Replacement, Brake Caliper/Rotor Replacement, Electrical Component Diagnosis and Replacement, Body Panel Repair

Special Procedures:

PCM/BCM Reprogramming, Key Fob Programming, Airbag System Service, ABS Bleeding, HVAC System Evacuation and Recharge (R134a/R1234yf if applicable for later models)

Technical Depth

Depth:

Comprehensive; covers basic maintenance to full engine and transmission rebuilds. Includes wiring diagrams, diagnostic procedures, and specifications.

📊 Manual Specifications

File Format

File Quality:

High-resolution, searchable PDF with selectable text and clear diagrams.

Print Compatibility:

Printable on standard home or office printers. Sections can be printed as needed.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.3L V6 OHV (EGA)

Engine 1 Displacement:

3301 cc (201.5 ci)

Engine 1 Bore X Stroke:

96.0 mm x 76.0 mm (3.78 in x 3.00 in)

Engine 1 Compression Ratio:

9.0:1

Engine 1 Horsepower Approx:

180-185 hp @ 5000-5200 rpm

Engine 1 Torque Approx:

200-205 lb-ft @ 3400-4000 rpm

Secondary Engine

Engine 2:

3.8L V6 OHV (L32)

Engine 2 Displacement:

3778 cc (230.5 ci)

Engine 2 Bore X Stroke:

96.0 mm x 87.0 mm (3.78 in x 3.43 in)

Engine 2 Compression Ratio:

8.4:1

Engine 2 Horsepower Approx:

200-215 hp @ 5000-5200 rpm

Engine 2 Torque Approx:

230-235 lb-ft @ 3000-4000 rpm

Tertiary Engine

Engine 3:

4.0L V6 SOHC (ЕНК)

Engine 3 Displacement:

3952 cc (241.2 ci)

Engine 3 Bore X Stroke:

96.0 mm x 90.9 mm (3.78 in x 3.58 in)

Engine 3 Compression Ratio:

9.1:1

Engine 3 Horsepower Approx:

240-250 hp @ 5800-6000 rpm

Engine 3 Torque Approx:

250-260 lb-ft @ 4000-4400 rpm

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Fuel Pump:

In-tank Electric

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Transmission Codes Common:

41TE, 42LE, 45RFE (depending on engine and year)

Optional

Optional Transmission:

None (All models were automatic)

Features

Transmission Features:

Electronically controlled, torque converter lock-up, selectable gear ranges (OD, 3, 2, 1).

Fluid Specifications

Transmission Fluid Type:

ATF+4 (Chrysler Material Standard MS-9602)

Fluid Capacities

Transmission Fluid Capacity Approx:

4.5-5.5 quarts (4.3-5.2 liters) - dry fill

📐 Dimensions

Exterior

Length Overall Approx:

199.5 - 200.5 inches (5067 - 5093 mm)

Width Without Mirrors Approx:

76.0 - 76.5 inches (1930 - 1943 mm)

Height Overall Approx:

68.0 - 69.0 inches (1727 - 1753 mm)

Wheelbase Approx:

119.2 inches (3028 mm)

Interior

Passenger Volume Approx:

140-160 cu ft (3964 - 4531 liters)

Cargo

Cargo Volume Behind 3Rd Row Approx:

30-40 cu ft (850 - 1132 liters)

Cargo Volume Behind 2Nd Row Approx:

75-90 cu ft (2124 - 2549 liters)

Cargo Volume Max Approx:

140-160 cu ft (3964 - 4531 liters)

Weights

Curb Weight Approx:

4100 - 4500 lbs (1860 - 2041 kg)

Gross Vehicle Weight Rating Gvwr Approx:

5700 - 6000 lbs (2585 - 2722 kg)

🛡️ Safety Features

Ratings

NHTSA Front Driver Side Impact Rating:

5 Stars (for most models in this range)

NHTSA Front Passenger Side Impact Rating:

5 Stars (for most models in this range)

NHTSA Side Driver Front Seat Rating:

4-5 Stars (depending on side airbags)

NHTSA Side Rear Passenger Rating:

4-5 Stars (depending on side airbags)

IIHS Moderate Overlap Front Rating:

Good (for most models in this range)

IIHS Side Impact Rating:

Good or Acceptable (depending on equipment)

Active Features

Standard

Traction Control:

Optional on some trims, standard on later models

Electronic Stability Control:

Optional on some trims, standard on later models

Passive Features

Airbags Front:

Standard (Driver and Passenger)

Airbags Side:

Optional (Front Seat-mounted, available side curtain airbags on later models)

Seatbelts:

3-point front and rear seatbelts, front seat pretensioners

💡 Technology Features

Infotainment

Infotainment Systems:

Base AM/FM/CD players, optional Infinity sound systems, optional rear-seat entertainment (DVD players).

Navigation:

Optional factory navigation system available on higher trim levels.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Assist:

Optional rear park assist sensors available on select trims.

Connectivity

Power Accessories:

Power windows, power locks, power sliding doors, power liftgate (depending on trim).

Remote Keyless Entry:

Standard on most models, with remote start on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plugs:

Replace every 100,000 miles (160,000 km) with recommended iridium or platinum-tipped plugs.

Transmission Fluid Change:

Inspect every 30,000 miles (48,000 km), change fluid and filter every 60,000 miles (96,000 km) or sooner under severe use. (ATF+4 is a 'fill for life' fluid in some applications, but proactive changes are recommended).

Coolant Replacement:

Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter (OAT coolant).

Fluid Specifications

Engine Oil Type Viscosity:

SAE 5W-30 (API Certified) for all engines. Check manual for specific oil quality certifications.

Coolant Type:

Chrysler OAT (Organic Acid Technology) Coolant - Pink Color (MS-12106 or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 (check specific year/model for preference).

Known Issues

Common Problem 1:

Transmission solenoid failures or internal wear leading to shifting problems or no-drive conditions, especially in higher-mileage units.

Common Problem 2:

Rear heat exchanger leaks (common in vehicles with rear climate control).

Common Problem 3:

Water pump failures and associated coolant leaks.

Common Problem 4:

Power sliding door module issues or cable binding.

Common Problem 5:

Chrysler's 'lifter tick' or 'cam follower' noise from the 3.3L/3.8L engines, often exacerbated by infrequent oil changes.

Common Repairs Covered

Engine Repair:

Head Gasket Replacement, Timing Chain/Belt Service (if applicable), Oil Pan Gasket, Valve Cover Gasket.

Transmission Repair:

Torque Converter Replacement, Valve Body Service, Seal Replacements, Cooler Line Repair.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1984, establishing the benchmark for family vehicles.

Model Evolution

Fourth Generation Rs:

The RS generation (2001-2007) featured updated styling, improved safety features, and the introduction of the 4.0L V6 engine and Stow 'n Go seating system (introduced mid-generation).

Trim Levels:

SE, SXT, ES, Limited, Touring, EX (depending on make and year)

Production

Manufacturing Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

Sales Trend:

Remained a strong seller in the minivan segment throughout its production run, though facing increasing competition.

🏆 Awards & Recognition

Recognitions

Initial Launch Accolades:

The fourth-generation platform generally received positive reviews for its packaging, practicality, and comfort, building on the success of its predecessors.

Safety Awards:

Often achieved good safety ratings from NHTSA and IIHS, reflecting improved structural integrity and airbag systems compared to earlier generations.

Industry Impact:

These models continued to define the practicality and utility of the minivan segment, with the Stow 'n Go system revolutionizing cargo and seating flexibility.