Dodge Caravan 2001-2007 Workshop Repair Service Manual
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๐ท๏ธ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 ๐ Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, fleet operators, DIY mechanics Competitive Analysis Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture Key Features Versatility: Flexible seating configurations, spacious interior, Stow 'n Go seating (later models) Value Proposition: Affordable family transportation with a strong emphasis on practicality and cargo capacity ๐ Manual Details Coverage Areas Primary Coverage: Workshop Repair Service Manual Scope: Maintenance, Service, Troubleshooting, Repair Format File Format: PDF Download Language Language: English ๐ Manual Coverage Systems Covered Engine: All engine types, including 2.4L, 3.3L V6, and 3.8L V6 Transmission: Automatic Transmissions (4-speed) Drivetrain: Front-Wheel Drive (FWD) Suspension Steering: Front McPherson strut, rear torsion beam axle; power steering system Brakes: Front disc, rear drum (standard); ABS system (optional) Electrical Lighting: Battery, charging system, ignition, lighting, instruments, power accessories, body control modules HVAC: Heating, ventilation, and air conditioning systems Fuel Exhaust: Fuel delivery, fuel injection, exhaust system, emissions control Body Interior: Exterior body panels, interior trim, seating, doors, liftgate, power sliding doors Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, coolant flush, brake fluid replacement Repair: Component replacement (alternator, starter, water pump, etc.), suspension component repair, brake system overhaul Troubleshooting: Diagnosis of engine performance, transmission issues, electrical faults, HVAC problems Specifications: Torque specifications, fluid capacities, electrical schematics, diagnostic procedures Technical Depth Depth: Comprehensive, covering routine maintenance to major component overhauls and complex diagnostics ๐ Manual Specifications File Format PDF Quality: High-resolution, text-searchable PDF for easy navigation and printing Printable: Printable pages for workshop use Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) โ๏ธ Engine Specifications Primary Engine Engine 1: 2.4L (2429cc) DOHC 16-valve Inline-4 (K24A or similar Chrysler designation) Engine 2: 3.3L (3301cc) OHV 12-valve V6 (Chrysler EGAN) Engine 3: 3.8L (3778cc) OHV 12-valve V6 (Chrysler L32) Performance Hp 2.4L: Approximately 150 hp @ 5900 rpm Torque 2.4L: Approximately 160 lb-ft @ 4000 rpm Hp 3.3L: Approximately 180 hp @ 4850 rpm Torque 3.3L: Approximately 205 lb-ft @ 4000 rpm Hp 3.8L: Approximately 190 hp @ 4750 rpm Torque 3.8L: Approximately 230 lb-ft @ 3400 rpm Fuel System Induction: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline ๐ง Transmission Standard Transmission Type: 41TE/AE 4-speed automatic transaxle Optional Transmission Options: None (4-speed automatic standard across most trims) Features Transmission Fluid: ATF+4 (Chrysler Material Standard MS-9602) Gear Ratios: Specific ratios detailed within the manual for each engine variant ๐ Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: Approximately 193.5 inches (4915 mm) Width: Approximately 76.7 inches (1948 mm) Height: Approximately 67.7 inches (1720 mm) Cargo Cargo Volume Behind 1St Row: Approx. 150.1 cu ft (4250 L) Cargo Volume Behind 2Nd Row: Approx. 93.1 cu ft (2636 L) Cargo Volume Behind 3Rd Row: Approx. 31.5 cu ft (892 L) Weights Curb Weight: Varies by engine and trim, typically 3900-4300 lbs Gross Vehicle Weight Rating: GVWR varies, typically 5700-6000 lbs Towing Capacity: Up to 3800 lbs (with optional towing package and appropriate engine) ๐ก๏ธ Safety Features Ratings NHTSA Front Impact: 4-star (driver and passenger) for 2001-2007 models (varies slightly by year/configuration) NHTSA Side Impact: 4-star (front and rear passenger) for 2001-2007 models (varies slightly by year/configuration) IIHS Small Overlap Frontal: Not rated (vehicles predate this specific testing protocol) Active Features ABS: Anti-lock Braking System (standard on most trims, optional on base models) Traction Control: Optional on some models, particularly with V6 engines Passive Features Airbags: Front driver and passenger airbags; optional side curtain airbags on later models Seatbelts: 3-point front and rear seat belts, LATCH child seat anchors ๐ก Technology Features Infotainment Audio Systems: Factory AM/FM/CD players; optional premium Infinity sound systems Rear Seat Entertainment: Optional rear-seat video entertainment systems available on some trims Driver Assistance Cruise Control: Standard cruise control Parking Sensors: Optional rear parking assist sensors Connectivity Auxiliary Input: Not standard; often required aftermarket installation for audio device connectivity ๐ง Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type (refer to manual for specific recommendations) Transmission Fluid Change: Every 30,000-60,000 miles (refer to manual for specific intervals and ATF+4 specification) Coolant Flush Interval: Every 30,000-50,000 miles or 3-5 years Fluid Specifications Engine Oil Type: SAE 5W-30 (or 10W-30 depending on climate, consult manual for exact OEM recommendation) Coolant Type: Mopar OAT (Organic Acid Technology) Antifreeze/Coolant (or equivalent) Brake Fluid Type: DOT 3 or DOT 4 brake fluid Known Issues Transmission Failures: Some models experienced transmission issues (slipping, harsh shifts), often related to fluid degradation or solenoids. Regular fluid changes are critical. Power Sliding Doors: Motor, track, and switch issues can affect the operation of power sliding doors. Ignition Switch Failure: Intermittent electrical issues or no-start...
Some models experienced transmission issues (slipping, harsh shifts), often related to fluid degradation or solenoids. Regular fluid changes are critical.
Power Sliding Doors:
Motor, track, and switch issues can affect the operation of power sliding doors.
Ignition Switch Failure:
Intermittent electrical issues or no-start conditions can be linked to a failing ignition switch.
Heater Core Leaks:
Leaking heater cores can cause coolant loss and a sweet odor inside the cabin.
Climate Control Actuators:
Faulty blend door actuators can cause HVAC temperature control problems.
๐ Vehicle History
Brand Heritage
Dodge History:
Dodge, a division of Chrysler, has a long history of producing practical and durable vehicles, including a significant presence in the minivan market.
Model Evolution
Generation:
Third Generation Dodge Caravan (NS platform, revised for 2001)
Design Changes:
Updated exterior styling, interior refinements, introduction of Stow 'n Go seating for 2005 model year. Enhanced safety features.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; Saltillo, Mexico
Production Years:
Third generation: 1996-2000; Fourth generation (this manual's coverage): 2001-2007
๐ Awards & Recognition
Recognitions
Consumer Reports Ratings:
Mixed ratings over the years, often praised for practicality and space, but with recurring reliability concerns in certain areas (e.g., transmission)
Jd Power Rankings:
Ratings vary by year and model; often positioned as a budget-friendly option in the minivan segment.