DODGE CARAVAN TOWN COUNTRY PLYMOUTH VOYAGER Service Repair Manual 2001-2006
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🏷️ Basic Information Identification Make: Dodge, Chrysler, Plymouth Model: Caravan, Town & Country, Voyager Generation Generation Code: RG (Chrysler), NS (Dodge/Plymouth) Codes Platform: NS/RS platform 👋 Introduction Market Position Vehicle Segment: Minivan Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Montana, Mercury Monterey Key Features Unique Selling Points Of Vehicles: Spacious interior, Stow 'n Go seating (introduced later in the generation, but foundational for the platform), versatile cargo capacity, comfortable ride, relatively affordable pricing 📋 Manual Details Coverage Areas Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Extensive (typically 1500-3000+ pages for full factory service manuals of this era) Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine Mechanical, Lubrication, Cooling, Fuel, Ignition, Emission Control, Starting, Charging Transmission Systems: Automatic Transmission (e.g., 41TE, 42LE, 45RFE, 42RLE), Manual Transmission (less common), Drivetrain, Axles, CV Joints Chassis Systems: Suspension (Front and Rear), Steering, Brakes (Hydraulic, ABS), Wheels and Tires Electrical Systems: Battery, Starting and Charging, Lighting, Instruments, Gauges, Warning Systems, Body Control Modules, Power Accessories (Windows, Doors, Seats), HVAC Controls, Audio Systems Body And Interior: Body Construction, Doors, Hood, Liftgate, Bumpers, Exterior Trim, Interior Trim, Seats, Restraint Systems (Airbags, Seatbelts) Procedures Included Maintenance Procedures: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Belt Inspections and Replacement, Spark Plug Replacement, Brake Pad/Rotor Replacement Diagnostic Procedures: On-Board Diagnostics (OBD-II) Scan Tool Procedures, DTC Code Explanations, System Circuit Diagnosis, Component Testing Repair Procedures: Engine Repair and Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Repair, Body Panel Repair, HVAC System Repair Troubleshooting Guides: Step-by-step troubleshooting for common symptoms and problems Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) 📊 Manual Specifications File Format File Type: Adobe PDF Print Quality Printability: High-quality, printable pages Binding Type Binding Type: Digital Download (Printable) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement Liters: 3.3L Engine 1 Cylinders: 6 Engine 1 Configuration: V6 (SOHC) Engine 1 Horsepower Hp: Approx. 180-185 hp Engine 1 Torque Lb Ft: Approx. 200-210 lb-ft Performance Engine 2 Displacement Liters: 3.8L Engine 2 Cylinders: 6 Engine 2 Configuration: V6 (OHV) Engine 2 Horsepower Hp: Approx. 200-215 hp Engine 2 Torque Lb Ft: Approx. 230-240 lb-ft Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline 🔧 Transmission Standard Transmission Type Standard: 4-Speed Automatic (e.g., 41TE/42LE) Optional Transmission Type Optional: 4-Speed Automatic (e.g., 45RFE/42RLE with select engines/models) Features Transmission Fluid Type: ATF+4 (Mopar) 📐 Dimensions Exterior Wheelbase Inches: Approx. 119.2 inches Length Inches: Approx. 195.5 - 202.6 inches (depending on model/wheelbase) Width Inches: Approx. 74.5 inches Height Inches: Approx. 68.1 inches Cargo Max Cargo Volume Cu Ft: Over 150 cu. ft. (with rear seats removed/stowed) Weights Curb Weight Lbs: Approx. 4000-4500 lbs (depending on configuration) Towing Capacity Lbs: Up to 3800 lbs (with optional towing package) 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating Driver: 4 stars (for models equipped with front airbags) NHTSA Frontal Crash Rating Passenger: 4 stars (for models equipped with front airbags) Active Features ABS: Standard or Optional (depending on trim/year) Traction Control: Optional (TCS) Passive Features Airbags: Frontal airbags standard; optional side airbags available on some models. Seatbelts: All seating positions equipped with three-point seat belts. 💡 Technology Features Infotainment Audio System Options: AM/FM Stereo with CD player, cassette player, optional premium audio systems with amplifiers and subwoofers. Rear Seat Entertainment: Optional rear-seat video entertainment system with screens and headphone jacks available on higher trims. Driver Assistance Cruise Control: Standard on most trims. Parking Assist: Optional rear parking assist sensors available. Connectivity Auxiliary Input: Not typically available in this era; aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change Interval Miles: Every 3,000-7,500 miles (depending on oil type used and driving conditions - consult manual for specifics) Transmission Fluid Change Interval Miles: Every 30,000-60,000 miles (severe service may require more frequent changes) Spark Plug Replacement Miles: Approx. 60,000-100,000 miles (depending on plug type - platinum/iridium recommended) Fluid Specifications Engine Oil Specification: API SN or newer, SAE 5W-30 (or 10W-30 depending on climate, consult manual) Coolant Specification: Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (e.g., 5 Year/100,000 Mile Formula) - Pink color Brake Fluid Specification: DOT 3 Known Issues Common Problem 1: Transmission issues (e.g., slipping, harsh shifting, particularly with the 41TE/42LE transmission, often related to solenoid pack or torque converter failure). Common Problem 2: Water pump leaks, especially common with the 3.3L and 3.8L OHV engines. Common Problem 3: CV joint wear and boot failure. Common Problem 4: Power sliding door mechanism issues (if equipped). Common Problem 5: Heater core leaks leading to interior moisture and coolant smell. 📚 Vehicle History Brand Heritage Parent Company: Chrysler...
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Montana, Mercury Monterey
Key Features
Unique Selling Points Of Vehicles:
Spacious interior, Stow 'n Go seating (introduced later in the generation, but foundational for the platform), versatile cargo capacity, comfortable ride, relatively affordable pricing
📋 Manual Details
Coverage Areas
Model Years Covered:
2001, 2002, 2003, 2004, 2005, 2006
Page Count
Estimated Page Count:
Extensive (typically 1500-3000+ pages for full factory service manuals of this era)
Suspension (Front and Rear), Steering, Brakes (Hydraulic, ABS), Wheels and Tires
Electrical Systems:
Battery, Starting and Charging, Lighting, Instruments, Gauges, Warning Systems, Body Control Modules, Power Accessories (Windows, Doors, Seats), HVAC Controls, Audio Systems
Body And Interior:
Body Construction, Doors, Hood, Liftgate, Bumpers, Exterior Trim, Interior Trim, Seats, Restraint Systems (Airbags, Seatbelts)
Procedures Included
Maintenance Procedures:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Belt Inspections and Replacement, Spark Plug Replacement, Brake Pad/Rotor Replacement
Transmission issues (e.g., slipping, harsh shifting, particularly with the 41TE/42LE transmission, often related to solenoid pack or torque converter failure).
Common Problem 2:
Water pump leaks, especially common with the 3.3L and 3.8L OHV engines.
Common Problem 3:
CV joint wear and boot failure.
Common Problem 4:
Power sliding door mechanism issues (if equipped).
Common Problem 5:
Heater core leaks leading to interior moisture and coolant smell.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later DaimlerChrysler)
Model Evolution
Generation Overview:
This generation represents a significant redesign for the minivans, offering improved styling, safety features, and powertrain options compared to previous generations. It was a crucial period for Chrysler's dominance in the minivan segment.
Production
Assembly Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Ward Top 10 Engines:
The 3.8L V6 was recognized by Ward's AutoWorld as one of the '10 Best Engines' in the past, highlighting its refinement and power delivery for its time.
Ratings
Consumer Reports Reliability:
Reliability ratings varied during this generation; specific model years and engines had different scores. The manual is essential for understanding common issues and their remedies.
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