DODGE CARAVAN 2000-2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Model Years: 2000, 2001, 2002 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Segment: Minivan Target Audience: Owners seeking to perform their own maintenance and repairs, independent repair shops. Competitive Analysis Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana. Key Selling Points: Practicality, seating capacity, versatility, affordability compared to luxury minivans. Key Features Manual Benefit: Enables significant cost savings on repairs and maintenance compared to dealership or independent shop labor rates. Manual Utility: Provides detailed, step-by-step instructions and diagnostic procedures that are essential for accurate repairs. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair for all systems. Specific Systems: Engine, Transmission, Brakes, Suspension, Steering, Electrical, HVAC, Body, Drivetrain. Page Count Estimated Pages: Over 1500 pages (typical for factory service manuals of this era). Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (likely PDF, searchable) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, engine control systems (ECM/PCM). Transmission Drivetrain: Automatic Transaxle (41TE/42LE), manual transaxle (less common), axles, drive shafts, differential. Chassis: Brake system (disc/drum, ABS), power steering, suspension (front struts, rear torsion bars/leaf springs), wheels and tires. Electrical Electronics: Battery, charging system, starting system, lighting, instruments, body control module (BCM), power windows/locks, audio system, factory alarms. HVAC: Air conditioning system, heating system, ventilation, climate control. Body Structure: Body panels, doors, interior trim, glass, bumpers, frame and unibody structure, collision repair basics. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections/replacement, brake pad/shoe replacement. Diagnostics Troubleshooting: Diagnostic Trouble Codes (DTCs), symptom-based troubleshooting guides, electrical circuit diagnostics. Repair Overhaul: Engine tune-ups, cylinder head removal/installation, transmission overhaul procedures, brake caliper/rotor replacement, suspension component replacement, starter/alternator replacement. Alignment Balancing: Wheel alignment specifications and procedures, tire balancing. Wiring Diagrams: Detailed electrical schematics for all major systems. Technical Depth Depth: Complete diagnostic and repair procedures, including specifications for torque values, clearances, fluid capacities, and component testing. Detail Level: Factory-level information suitable for professional technicians and highly skilled DIYers. 📊 Manual Specifications File Format Digital Quality: High-resolution, searchable PDF with clear diagrams and text. Print Quality Printability: Designed for easy printing of individual sections or the entire manual. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 3.3L V6 (EGA) Displacement 1: 3301 cc (201.5 cubic inches) Configuration 1: Overhead Valve (OHV), 60-degree V6 Horsepower 1: Approx. 180 hp @ 5000 rpm Torque 1: Approx. 210 lb-ft @ 3600 rpm Optional Engine Engine Code 2: 2.4L 4-Cylinder (EDZ - less common in later years of this generation) Displacement 2: 2429 cc (148.2 cubic inches) Configuration 2: Overhead Valve (OHV), Inline-4 Horsepower 2: Approx. 150 hp @ 5200 rpm Torque 2: Approx. 170 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type 1: 4-Speed Automatic Transaxle (41TE/42LE) Optional Transmission Type 2: 5-Speed Manual Transaxle (less common) Features Transmission Features: Lock-up torque converter, electronic pressure control. 📐 Dimensions Exterior Wheelbase: Approx. 112.1 inches Length: Approx. 189.7 inches Width: Approx. 72.0 inches Height: Approx. 67.9 inches Cargo Max Cargo Volume: Approx. 145.9 cubic feet (with rear seats removed) Weights Curb Weight: Approx. 3800 - 4200 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (2000 Model Year) NHTSA Front Impact Passenger: 4 Stars (2000 Model Year) NHTSA Side Impact Front Driver: Not Rated (Typical for this era) NHTSA Side Impact Front Passenger: Not Rated (Typical for this era) IIHS Moderate Overlap Front: Good (2000 Model Year) Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Optional on some models Passive Features Airbags: Driver and front passenger airbags standard. Optional side airbags. 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette and/or CD player, optional premium audio systems available. Display: Basic digital or analog displays for radio and climate controls. Driver Assistance Cruise Control: Standard on most models. Rear Parking Assist: Optional on some models. Connectivity Auxiliary Input: Not typically standard, aftermarket solutions available. Remote Keyless Entry: Optional on many trims. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (refer to manual for specifics). Transmission Fluid Change: Every 30,000-60,000 miles for automatic transaxles (ATF+4 recommended). Spark Plugs Replacement: Typically every 60,000-100,000 miles for platinum or iridium plugs. Coolant Flush: Every 30,000-100,000 miles or 2-5 years (check coolant type and manual recommendations). Fluid Specifications Engine Oil: SAE 5W-30 or 5W-40 (check owner's manual for specific API service category, e.g., API SN or equivalent). Transmission Fluid: Mopar ATF+4 (MS-9602) Coolant: Chrysler Type I (OAT - Organic Additive Technology) or Type II (HOAT - Hybrid...
Approx. 3800 - 4200 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (2000 Model Year)
NHTSA Front Impact Passenger:
4 Stars (2000 Model Year)
NHTSA Side Impact Front Driver:
Not Rated (Typical for this era)
NHTSA Side Impact Front Passenger:
Not Rated (Typical for this era)
IIHS Moderate Overlap Front:
Good (2000 Model Year)
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Optional on some models
Passive Features
Airbags:
Driver and front passenger airbags standard. Optional side airbags.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and/or CD player, optional premium audio systems available.
Display:
Basic digital or analog displays for radio and climate controls.
Driver Assistance
Cruise Control:
Standard on most models.
Rear Parking Assist:
Optional on some models.
Connectivity
Auxiliary Input:
Not typically standard, aftermarket solutions available.
Remote Keyless Entry:
Optional on many trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (refer to manual for specifics).
Transmission Fluid Change:
Every 30,000-60,000 miles for automatic transaxles (ATF+4 recommended).
Spark Plugs Replacement:
Typically every 60,000-100,000 miles for platinum or iridium plugs.
Coolant Flush:
Every 30,000-100,000 miles or 2-5 years (check coolant type and manual recommendations).
Fluid Specifications
Engine Oil:
SAE 5W-30 or 5W-40 (check owner's manual for specific API service category, e.g., API SN or equivalent).
Transmission Fluid:
Mopar ATF+4 (MS-9602)
Coolant:
Chrysler Type I (OAT - Organic Additive Technology) or Type II (HOAT - Hybrid Organic Additive Technology) for later models, typically a 50/50 mix with distilled water. Check manual for specific type.
Brake Fluid:
DOT 3
Power Steering Fluid:
Chrysler Power Steering Fluid (Mopar) or equivalent ATF compatible with older Chrysler systems.
Blend door actuator failures, blower motor resistor failure, AC refrigerant leaks.
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan in 1984, setting the standard for family vehicles.
Model Evolution
Generation:
Third Generation (NS) from 1996-2000, facelifted for 2001-2007 (RS platform, but sharing many components with late NS models for service purposes, hence the combined year range coverage).
2001 Update:
Significant styling refresh for 2001, including updated interior, exterior, and some powertrain improvements, though the core engineering remains related to the preceding years.
Often recognized by automotive publications for its practicality and value in the minivan segment during its production run.
Ratings
Consumer Reports Reliability:
Mixed, with some years/components showing average to below-average reliability, particularly regarding the powertrain and electronics. The service manual is crucial for addressing these.
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