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Dodge Caravan 2000-2007 Online Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Codes Chassis Code: RS (Third Generation) Platform: Chrysler RS Platform 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families, individuals needing versatile cargo and passenger space. Competitive Analysis Key Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana SV6. Key Features Versatility: Known for its flexible interior seating (Stow 'n Go introduced later in the generation, but the basic platform offered good space), ample cargo room, and comfortable ride. Powertrain Options: Offered a choice of reliable V6 engines providing adequate power for a vehicle of its size and purpose. Value Proposition: Often positioned as a more affordable alternative to some competitors while maintaining strong functionality. 📋 Manual Details Coverage Areas Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Trim Levels Covered: All available trim levels (e.g., SE, SXT, ES, RT) Page Count Estimated Page Count: 2500+ Manual Type Type: Factory Authorized Service and Repair Manual Language Language: English Format Format: Digital (likely PDF, potentially HTML) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, and overhaul for all gasoline engines including: 2.4L DOHC (G4HC), 3.3L OHV V6 (EGA), 3.8L OHV V6 (EGH) Transmission: Service and repair for automatic transmissions: 4-Speed 41TE/42LE (FWD), including torque converter, valve body, and electronic controls. Brakes: Front and rear disc brake systems, ABS (Anti-lock Braking System), parking brake, hydraulic system components, bleeding procedures. Electrical: Complete wiring diagrams, component testing, starter, alternator, battery, lighting systems, power windows, power locks, HVAC controls, dashboard instruments. Suspension Steering: Front McPherson strut suspension, rear torsion beam axle, power steering system, steering column, wheel alignment specifications. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, compressor, condenser, evaporator, blower motor, climate control module. Body Interior: Body panel removal/installation, doors, liftgate, interior trim, seating systems, airbags, seat belts, body sealing. Procedures Included Maintenance: Routine oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad replacement, tire rotations. Troubleshooting: Diagnostic flowcharts for common and complex issues, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation and resolution. Repair: Step-by-step instructions for engine component repair (e.g., head gasket, timing belt/chain), transmission overhaul, brake caliper replacement, CV joint replacement, fuel pump replacement, alternator replacement. Diagnostics: Information on using diagnostic scan tools, interpreting live data, performing component tests, and understanding electronic control module (ECM) functions. Technical Depth Depth: Comprehensive, from basic maintenance to advanced diagnostics and full component rebuilds. Includes specifications, tolerances, and torque values for critical fasteners. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Fully searchable text for quick information retrieval. Printability: Printable pages for physical reference. Print Quality Image Quality: High-resolution images, diagrams, and schematics. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: G4HC Displacement 1: 2.4 Liters (2429 cc) Configuration 1: Inline 4-Cylinder, DOHC Horsepower 1: 150 hp @ 5900 rpm Torque 1: 165 lb-ft @ 4500 rpm Secondary Engine Engine Code 2: EGA Displacement 2: 3.3 Liters (3301 cc) Configuration 2: V6, OHV, 12 Valves Horsepower 2: 180 hp @ 5000 rpm Torque 2: 205 lb-ft @ 4000 rpm Tertiary Engine Engine Code 3: EGH Displacement 3: 3.8 Liters (3778 cc) Configuration 3: V6, OHV, 12 Valves Horsepower 3: 200-215 hp @ 5200-5400 rpm (depending on year/application) Torque 3: 235-245 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline 🔧 Transmission Standard Transmission Type 1: 4-Speed Automatic (41TE/42LE) Drive Type: Front-Wheel Drive (FWD) Optional Transmission Type 2: None (4-speed automatic was standard across most models) Features Features: Electronically controlled, Adaptive transmission logic, Lock-up torque converter. Fluid Specifications Transmission Fluid Type: ATF+4 (MS-9602) or equivalent Dexron III/Mercon Fluid Capacities Transmission Fluid Capacity: Approx. 9.5 - 11.5 quarts (9.0 - 10.9 liters) (check dipstick for accurate level) 📐 Dimensions Exterior Length: Approx. 181.5 - 184.7 inches (4610 - 4691 mm) (depending on configuration) Width: Approx. 72.0 inches (1829 mm) Height: Approx. 67.5 - 68.5 inches (1715 - 1740 mm) Wheelbase: Approx. 112.1 inches (2847 mm) Interior Passenger Volume: Approx. 140 - 150 cubic feet (3964 - 4248 liters) Cargo Cargo Volume Behind 1St Row: Approx. 140 - 155 cubic feet (3964 - 4389 liters) Cargo Volume Behind 2Nd Row: Approx. 50 - 70 cubic feet (1416 - 1982 liters) Weights Curb Weight: Approx. 3600 - 4100 lbs (1633 - 1860 kg) (depending on engine and options) Gross Vehicle Weight Rating Gvwr: Approx. 5300 - 5800 lbs (2404 - 2631 kg) Towing Capacity: Up to 3800 lbs (1724 kg) (with optional towing package) 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: Good (for models tested) NHTSA Frontal Passenger Rating: Good (for models tested) IIHS Side Impact Rating: Acceptable or Good (depending on year and specific testing) Active Features ABS: Standard...
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Dodge Caravan 2000-2007 Online Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Codes
Chassis Code:
RS (Third Generation)
Platform:
Chrysler RS Platform
👋 Introduction
Market Position
Segment:
Mid-size Minivan
Target Audience:
Families, individuals needing versatile cargo and passenger space.
Competitive Analysis
Key Competitors:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana SV6.
Key Features
Versatility:
Known for its flexible interior seating (Stow 'n Go introduced later in the generation, but the basic platform offered good space), ample cargo room, and comfortable ride.
Powertrain Options:
Offered a choice of reliable V6 engines providing adequate power for a vehicle of its size and purpose.
Value Proposition:
Often positioned as a more affordable alternative to some competitors while maintaining strong functionality.
📋 Manual Details
Coverage Areas
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Trim Levels Covered:
All available trim levels (e.g., SE, SXT, ES, RT)
Page Count
Estimated Page Count:
2500+
Manual Type
Type:
Factory Authorized Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, potentially HTML)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul for all gasoline engines including: 2.4L DOHC (G4HC), 3.3L OHV V6 (EGA), 3.8L OHV V6 (EGH)
Transmission:
Service and repair for automatic transmissions: 4-Speed 41TE/42LE (FWD), including torque converter, valve body, and electronic controls.
Brakes:
Front and rear disc brake systems, ABS (Anti-lock Braking System), parking brake, hydraulic system components, bleeding procedures.
Electrical:
Complete wiring diagrams, component testing, starter, alternator, battery, lighting systems, power windows, power locks, HVAC controls, dashboard instruments.
Suspension Steering:
Front McPherson strut suspension, rear torsion beam axle, power steering system, steering column, wheel alignment specifications.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, compressor, condenser, evaporator, blower motor, climate control module.
Body Interior:
Body panel removal/installation, doors, liftgate, interior trim, seating systems, airbags, seat belts, body sealing.
Procedures Included
Maintenance:
Routine oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad replacement, tire rotations.
Troubleshooting:
Diagnostic flowcharts for common and complex issues, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation and resolution.
Repair:
Step-by-step instructions for engine component repair (e.g., head gasket, timing belt/chain), transmission overhaul, brake caliper replacement, CV joint replacement, fuel pump replacement, alternator replacement.
Diagnostics:
Information on using diagnostic scan tools, interpreting live data, performing component tests, and understanding electronic control module (ECM) functions.
Technical Depth
Depth:
Comprehensive, from basic maintenance to advanced diagnostics and full component rebuilds. Includes specifications, tolerances, and torque values for critical fasteners.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for physical reference.
Print Quality
Image Quality:
High-resolution images, diagrams, and schematics.
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
G4HC
Displacement 1:
2.4 Liters (2429 cc)
Configuration 1:
Inline 4-Cylinder, DOHC
Horsepower 1:
150 hp @ 5900 rpm
Torque 1:
165 lb-ft @ 4500 rpm
Secondary Engine
Engine Code 2:
EGA
Displacement 2:
3.3 Liters (3301 cc)
Configuration 2:
V6, OHV, 12 Valves
Horsepower 2:
180 hp @ 5000 rpm
Torque 2:
205 lb-ft @ 4000 rpm
Tertiary Engine
Engine Code 3:
EGH
Displacement 3:
3.8 Liters (3778 cc)
Configuration 3:
V6, OHV, 12 Valves
Horsepower 3:
200-215 hp @ 5200-5400 rpm (depending on year/application)
Torque 3:
235-245 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type 1:
4-Speed Automatic (41TE/42LE)
Drive Type:
Front-Wheel Drive (FWD)
Optional
Transmission Type 2:
None (4-speed automatic was standard across most models)
Features
Features:
Electronically controlled, Adaptive transmission logic, Lock-up torque converter.
Fluid Specifications
Transmission Fluid Type:
ATF+4 (MS-9602) or equivalent Dexron III/Mercon
Fluid Capacities
Transmission Fluid Capacity:
Approx. 9.5 - 11.5 quarts (9.0 - 10.9 liters) (check dipstick for accurate level)
📐 Dimensions
Exterior
Length:
Approx. 181.5 - 184.7 inches (4610 - 4691 mm) (depending on configuration)
Width:
Approx. 72.0 inches (1829 mm)
Height:
Approx. 67.5 - 68.5 inches (1715 - 1740 mm)
Wheelbase:
Approx. 112.1 inches (2847 mm)
Interior
Passenger Volume:
Approx. 140 - 150 cubic feet (3964 - 4248 liters)
Cargo
Cargo Volume Behind 1St Row:
Approx. 140 - 155 cubic feet (3964 - 4389 liters)
Cargo Volume Behind 2Nd Row:
Approx. 50 - 70 cubic feet (1416 - 1982 liters)
Weights
Curb Weight:
Approx. 3600 - 4100 lbs (1633 - 1860 kg) (depending on engine and options)
Gross Vehicle Weight Rating Gvwr:
Approx. 5300 - 5800 lbs (2404 - 2631 kg)
Towing Capacity:
Up to 3800 lbs (1724 kg) (with optional towing package)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Rating:
Good (for models tested)
NHTSA Frontal Passenger Rating:
Good (for models tested)
IIHS Side Impact Rating:
Acceptable or Good (depending on year and specific testing)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Available Traction Control System (TCS) on some later models.
Passive Features
Airbags:
Front driver and passenger airbags. Optional side airbags were available on some later models.
Seatbelts:
3-point front and rear seat belts, shoulder belt height adjusters, driver seat belt reminder.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD/Cassette players. Optional Infinity premium audio systems available. Rear entertainment systems (DVD player) introduced on some later models.
Navigation:
Factory navigation systems were an option on higher trim levels in later model years.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Parking Assist:
Rear parking assist sensors were an option on some later models.
Connectivity
Phone Integration:
Limited connectivity options. Bluetooth integration was not standard in this era. Aftermarket solutions are common.
Other Features
Power Features:
Power windows, power door locks, power mirrors, power sliding doors (optional), power liftgate (optional on some later models).
Remote Keyless Entry:
Available remote keyless entry system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6 months, depending on driving conditions and oil type used (consult manual for specific recommendation).
Engine Air Filter Replacement:
Every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000 to 20,000 miles (24,000 to 32,000 km) or annually.
Spark Plug Replacement:
Approx. 60,000 to 100,000 miles (96,000 to 160,000 km) for platinum or iridium plugs (specific interval depends on plug type and engine).
Coolant Flush Replacement:
Every 30,000 to 50,000 miles (48,000 to 80,000 km) or 2-3 years.
Transmission Fluid Change:
Every 30,000 to 60,000 miles (48,000 to 96,000 km) under normal driving conditions. Severe conditions may require more frequent changes.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (preferred for most conditions), SAE 10W-30 or 10W-40 may be acceptable in specific temperature ranges (consult manual).
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) for 2.4L, 4.5 quarts (4.3 liters) for 3.3L, 5.0 quarts (4.7 liters) for 3.8L (with filter change, always verify with dipstick).
Coolant Type:
Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (typically Mopar OAT or equivalent).
Brake Fluid Type:
DOT 3 or DOT 4 Brake Fluid.
Known Issues
Common Problems 1:
Transmission problems, particularly with earlier 4-speed automatics (shift solenoid issues, torque converter clutch shudder).
Common Problems 2:
Ignition coil failure, spark plug wire issues (on models with distributor ignition). Power window regulators can fail.
Common Problems 3:
Suspension wear (ball joints, tie rod ends, sway bar links) due to vehicle weight and use.
Common Problems 4:
EGR valve clogging, especially with the 3.3L and 3.8L engines, leading to rough idle or stalling.
Common Problems 5:
Climate control module failures, leading to HVAC system malfunctions.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge, a division of Chrysler (now Stellantis), has a long history of producing reliable and practical vehicles, including their pioneering minivan offerings.
Model Evolution
Generation:
This period covers the third generation (RS) of the Dodge Caravan, launched in 1996 and significantly updated for the 2001 model year (often referred to as a mid-cycle refresh for the third generation).
Key Updates 2001:
Revised exterior styling, updated interior design, introduction of more powerful engine options, improved safety features, and enhancement of minivan technologies.
Production
Manufacturing Locations:
Primarily built in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.
Sales Context:
The Dodge Caravan, along with its Chrysler Town & Country and Plymouth Voyager siblings, were best-selling minivans for much of their production run, defining the segment.
🏆 Awards & Recognition
Recognitions
Consumer Reports:
Varied ratings over the years; generally praised for practicality and value but sometimes criticized for reliability in specific areas.
Jd Power:
Typically received average to above-average ratings for initial quality and dependability in its class during its production run.
Certifications
Safety Certifications:
Met all federal motor vehicle safety standards (FMVSS) in place for the respective model years.
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