2001-2007 DODGE CARAVAN Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, fleet operators, DIY mechanics, automotive enthusiasts. Competitive Analysis Competitors: Toyota Sienna, Honda Odyssey, Ford Freestar/Windstar, Chevrolet Venture/Montana. Key Features Vehicle Strengths: Spacious interior, flexible seating, good cargo capacity, available Stow 'n Go seating (on later models), comfortable ride. Manual Value Proposition: Empowers owners to perform maintenance and repairs, saving significant costs compared to dealership or independent shop labor. Manual Completeness: Extensive coverage for nearly all repair and maintenance tasks. 📋 Manual Details Coverage Areas Language: English Manual Type: Service and Repair Manual Format: PDF Page Count Approximate Page Count: 2000+ 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block, pistons, connecting rods, crankshaft, timing system (belts/chains), lubrication system, cooling system. Engine Performance: Fuel delivery system (injectors, pumps, lines), ignition system (spark plugs, coils, timing), emissions control, exhaust system. Transmission Automatic: Overhaul, diagnostic procedures, valve body, torque converter, gear sets, fluid capacities, filter replacement, electronic controls. Transmission Manual: Overhaul, clutch system, gear linkages, fluid specifications, diagnostic procedures. Drivetrain: Front-wheel drive axle shafts, CV joints, differential, wheel bearings. Suspension: Front suspension (struts, control arms, ball joints, bushings), rear suspension (shock absorbers, springs, trailing arms), alignment specifications. Steering: Power steering system, steering rack, column, linkages, fluid specifications. Brakes: Front and rear disc brake systems, ABS (Anti-lock Braking System) components and diagnostics, hydraulic system, parking brake. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, horn, wipers, power accessories. Body And Chassis: Body panel removal and installation, doors, hood, liftgate, interior trim, seats, glass, structural components. Climate Control: HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control modules. Comfort And Convenience: Power windows, power locks, power seats, remote keyless entry, interior lighting, rear entertainment systems (if applicable). Procedures Included Scheduled Maintenance: Oil change intervals, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement. Engine Repair: Complete engine rebuild procedures, head gasket replacement, timing belt/chain service, piston and ring replacement, valve guide seals. Transmission Repair: Internal transmission component replacement, torque converter installation, clutch replacement, transmission fluid flush and fill. Brake Service: Brake pad and rotor replacement, brake caliper service, brake fluid bleeding, ABS component replacement. Suspension And Steering Repair: Strut and shock replacement, ball joint and tie rod end replacement, power steering pump and rack replacement, wheel alignment procedures. Electrical Diagnostics: Troubleshooting electrical circuits using wiring diagrams, component testing, battery and charging system diagnosis. Body Repair: Door panel removal, liftgate mechanism repair, glass replacement, interior trim installation. Climate Control Repair: A/C system recharging, component replacement (compressor, evaporator, condenser), heater core replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems. Technical Depth Depth Of Coverage: Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format File Type: Digital (PDF) Searchability: Searchable text content Printability: Printable pages Print Quality Illustration Clarity: High-resolution diagrams and illustrations Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L (2429cc) 4-cylinder (2.4L DOHC I4), 3.3L (3301cc) V6 (3.3L OHV V6), 3.8L (3778cc) V6 (3.8L OHV V6), 3.8L Supercharged V6 (specific models). Performance 2.4L 4-Cylinder (Naturally Aspirated): Horsepower: ~150 hp @ 5800 rpm; Torque: ~165 lb-ft @ 4000 rpm 3.3L V6 (Naturally Aspirated): Horsepower: ~180 hp @ 5000 rpm; Torque: ~205 lb-ft @ 4000 rpm 3.8L V6 (Naturally Aspirated): Horsepower: ~200 hp @ 5000 rpm; Torque: ~235 lb-ft @ 3200 rpm 3.8L V6 (Supercharged): Horsepower: ~215 hp @ 5200 rpm; Torque: ~245 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Unleaded gasoline Fuel Tank Capacity: ~20 gallons (varies slightly by model year) 🔧 Transmission Standard Transmission Type Standard: 4-speed automatic transaxle (42LE) Optional Transmission Type Optional: 5-speed manual transaxle (less common, primarily on base models) Features Automatic Transmission Features: Electronically controlled, adaptive shifting logic. Fluid Specifications Automatic Transmission Fluid Type: Chrysler ATF+4 (MS-9602) Fluid Capacities Automatic Transmission Fluid Capacity: ~9.5 quarts (dry fill); ~5 quarts (drain and refill) 📐 Dimensions Exterior Length: ~190-193 inches (depending on configuration) Width: ~72 inches Height: ~68-69 inches Wheelbase: ~119-120 inches Cargo Max Cargo Volume: ~140-160 cubic feet (with rear seats removed/folded) Weights Curb Weight: ~3800-4300 lbs (depending on engine and configuration) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Generally rated 'Good' or 'Acceptable' for the period, with variations by year. NHTSA Front Impact Passenger: Generally rated 'Good' or 'Acceptable' for the period, with variations by year. IIHS Front Offset Test: Mixed results for the period; some models received 'Good', others 'Acceptable' or 'Marginal'. Active Features ABS: Standard on most models, optional on some...

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Tipo: Car

Fabricante:

Sku: 272599

Coleções: ALL Dodge

Disponibilidade: Em estoque

Tag: 2001 2002 2003 2004 2005 2006 2007 Car CARAVAN Cars Dodge Misc

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Model Years Covered:

2001, 2002, 2003, 2004, 2005, 2006, 2007

👋 Introduction

Market Position

Vehicle Segment:

Minivan

Target Audience:

Families, fleet operators, DIY mechanics, automotive enthusiasts.

Competitive Analysis

Competitors:

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

Key Features

Vehicle Strengths:

Spacious interior, flexible seating, good cargo capacity, available Stow 'n Go seating (on later models), comfortable ride.

Manual Value Proposition:

Empowers owners to perform maintenance and repairs, saving significant costs compared to dealership or independent shop labor.

Manual Completeness:

Extensive coverage for nearly all repair and maintenance tasks.

📋 Manual Details

Coverage Areas

Language:

English

Manual Type:

Service and Repair Manual

Format:

Page Count

Approximate Page Count:

2000+

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block, pistons, connecting rods, crankshaft, timing system (belts/chains), lubrication system, cooling system.

Engine Performance:

Fuel delivery system (injectors, pumps, lines), ignition system (spark plugs, coils, timing), emissions control, exhaust system.

Transmission Automatic:

Overhaul, diagnostic procedures, valve body, torque converter, gear sets, fluid capacities, filter replacement, electronic controls.

Transmission Manual:

Overhaul, clutch system, gear linkages, fluid specifications, diagnostic procedures.

Drivetrain:

Front-wheel drive axle shafts, CV joints, differential, wheel bearings.

Suspension:

Front suspension (struts, control arms, ball joints, bushings), rear suspension (shock absorbers, springs, trailing arms), alignment specifications.

Steering:

Power steering system, steering rack, column, linkages, fluid specifications.

Brakes:

Front and rear disc brake systems, ABS (Anti-lock Braking System) components and diagnostics, hydraulic system, parking brake.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system, horn, wipers, power accessories.

Body And Chassis:

Body panel removal and installation, doors, hood, liftgate, interior trim, seats, glass, structural components.

Climate Control:

HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control modules.

Comfort And Convenience:

Power windows, power locks, power seats, remote keyless entry, interior lighting, rear entertainment systems (if applicable).

Procedures Included

Scheduled Maintenance:

Oil change intervals, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement.

Engine Repair:

Complete engine rebuild procedures, head gasket replacement, timing belt/chain service, piston and ring replacement, valve guide seals.

Transmission Repair:

Internal transmission component replacement, torque converter installation, clutch replacement, transmission fluid flush and fill.

Brake Service:

Brake pad and rotor replacement, brake caliper service, brake fluid bleeding, ABS component replacement.

Suspension And Steering Repair:

Strut and shock replacement, ball joint and tie rod end replacement, power steering pump and rack replacement, wheel alignment procedures.

Electrical Diagnostics:

Troubleshooting electrical circuits using wiring diagrams, component testing, battery and charging system diagnosis.

Body Repair:

Door panel removal, liftgate mechanism repair, glass replacement, interior trim installation.

Climate Control Repair:

A/C system recharging, component replacement (compressor, evaporator, condenser), heater core replacement.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides.

Wiring Diagrams:

Detailed electrical wiring schematics for all vehicle systems.

Technical Depth

Depth Of Coverage:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Searchable text content

Printability:

Printable pages

Print Quality

Illustration Clarity:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.4L (2429cc) 4-cylinder (2.4L DOHC I4), 3.3L (3301cc) V6 (3.3L OHV V6), 3.8L (3778cc) V6 (3.8L OHV V6), 3.8L Supercharged V6 (specific models).

Performance

2.4L 4-Cylinder (Naturally Aspirated):

Horsepower: ~150 hp @ 5800 rpm; Torque: ~165 lb-ft @ 4000 rpm

3.3L V6 (Naturally Aspirated):

Horsepower: ~180 hp @ 5000 rpm; Torque: ~205 lb-ft @ 4000 rpm

3.8L V6 (Naturally Aspirated):

Horsepower: ~200 hp @ 5000 rpm; Torque: ~235 lb-ft @ 3200 rpm

3.8L V6 (Supercharged):

Horsepower: ~215 hp @ 5200 rpm; Torque: ~245 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

~20 gallons (varies slightly by model year)

🔧 Transmission

Standard

Transmission Type Standard:

4-speed automatic transaxle (42LE)

Optional

Transmission Type Optional:

5-speed manual transaxle (less common, primarily on base models)

Features

Automatic Transmission Features:

Electronically controlled, adaptive shifting logic.

Fluid Specifications

Automatic Transmission Fluid Type:

Chrysler ATF+4 (MS-9602)

Fluid Capacities

Automatic Transmission Fluid Capacity:

~9.5 quarts (dry fill); ~5 quarts (drain and refill)

📐 Dimensions

Exterior

Length:

~190-193 inches (depending on configuration)

Width:

~72 inches

Height:

~68-69 inches

Wheelbase:

~119-120 inches

Cargo

Max Cargo Volume:

~140-160 cubic feet (with rear seats removed/folded)

Weights

Curb Weight:

~3800-4300 lbs (depending on engine and configuration)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Generally rated 'Good' or 'Acceptable' for the period, with variations by year.

NHTSA Front Impact Passenger:

Generally rated 'Good' or 'Acceptable' for the period, with variations by year.

IIHS Front Offset Test:

Mixed results for the period; some models received 'Good', others 'Acceptable' or 'Marginal'.

Active Features

Standard on most models, optional on some base trims.

Traction Control:

Available on select models, especially with V6 engines.

Passive Features

Airbags:

Front airbags (driver and passenger) standard; optional side airbags.

Seat Belts:

Three-point seat belts for all seating positions; integrated child seat anchors.

💡 Technology Features

Infotainment

Infotainment System:

Base models featured a basic AM/FM stereo with CD player. Higher trims offered premium sound systems, in-dash CD changers, and optional rear-seat entertainment systems (DVD players).

User Interface:

Conventional button-based controls for audio and climate, with some models featuring early navigation systems.

Driver Assistance

Driver Assistance Features:

Limited by modern standards; ABS and optional traction control were the primary active safety aids. Electronic Stability Control (ESC) became available and more common in later model years.

Connectivity

Connectivity Options:

No integrated Bluetooth or USB ports in early models. Some later models might have offered auxiliary input jacks for audio devices.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 6-12 months, depending on oil type (conventional vs. synthetic) and driving conditions, as specified by Chrysler maintenance schedules.

Air Filter Replacement:

Every 30,000 miles or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000-30,000 miles or annually.

Spark Plug Replacement 4Cyl:

3.3L/3.8L V6: 100,000 miles (Platinum/Iridium plugs); 2.4L 4-Cyl: 60,000-100,000 miles (depending on plug type).

Timing Belt Replacement:

2.4L 4-cylinder: Every 90,000-100,000 miles. V6 engines use timing chains, which are generally maintenance-free unless issues arise.

Fluid Specifications

Engine Oil Specification:

SAE 5W-20 or 5W-30 (API Certified, meeting Chrysler MS-6395 specification).

Coolant Specification:

Chrysler OAT (Organic Additive Technology) Antifreeze/Coolant, typically HOAT coolant that meets MS-9769 or MS-12106 specification (specific color may vary, but often orange/red).

Brake Fluid Specification:

DOT 3 or DOT 4 (check specific manual for exact requirement).

Fluid Capacities

Engine Oil Capacity:

2.4L 4-cyl: ~4.5 quarts; 3.3L/3.8L V6: ~4.0 quarts (with filter change).

Coolant Capacity:

~11.5-12.5 quarts (depending on engine and heater core size).

Known Issues

Common Problem Transmission:

Overheating, solenoid failures, torque converter shudder (especially in 42LE transmissions). Fluid and filter changes are critical.

Common Problem Engine:

Head gasket leaks (especially 3.3L/3.8L), oil leaks from valve covers or oil pan, intake manifold gasket leaks (less common on this generation).

Common Problem Suspension:

Worn control arm bushings, worn ball joints, strut mount failures leading to noise and poor handling.

Common Problem Electrical:

Faulty window regulators, intermittent door lock issues, instrument cluster failures (gauge sweep problems), PCM (Powertrain Control Module) failures.

Common Problem HVAC:

Blend door actuator failures, blower motor resistor issues, refrigerant leaks in A/C system.

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan/Voyager in the early 1980s, establishing a strong market presence.

Model Evolution

Third Generation Design:

This generation (GS platform) introduced a more modern design, improved aerodynamics, and enhanced safety features over its predecessor.

Key Updates During Generation:

Introduction of available Stow 'n Go seating (2005), powertrain refinements, revised styling, and electronic stability control (ESC) becoming more prevalent.

Production

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada's assembly plant).

Production Run:

July 2000 to August 2007 for the 2001-2007 model years.

🏆 Awards & Recognition

Recognitions

Car And Driver Towing Capacity:

Not typically a focus of awards for minivans of this era, but capable of light towing within its Gross Combined Weight Rating.

Consumer Reports Reliability:

Varied throughout the model years and engine options. Some years/configurations were rated average, others below average in reliability surveys.

Certifications

Fuel Economy Ratings:

EPA estimates varied by engine and configuration. 4-cylinder models offered better MPG, while V6 models provided more power.