DODGE CARVAN TOWN & COUNTRY VOYAGER Workshop Repair Manual All 2001-2006 ModelS COVERED
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🏷️ Basic Information Identification Make: Dodge Model: Voyager Model Variant: Minivan Applicable Model Years: 2001, 2002, 2003, 2004, 2005, 2006 Codes Platform: NS (updated) 👋 Introduction Market Position Segment: Full-size minivan, family vehicle. Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza. Key Features Versatility: Renowned for its spacious interior, flexible seating options (including Stow 'n Go on later models), and practical cargo hauling capabilities. Powertrain Options: Offered with reliable V6 engines, providing a balance of power and efficiency for a large vehicle. Manual Purpose Target Audience: DIY mechanics, independent repair shops, fleet maintenance technicians. 📋 Manual Details Coverage Areas Geographical Coverage: North America Regional Specifications: USA, Canada Page Count Estimated Pages: Thousands (comprehensive workshop manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission (Automatic, Manual if applicable), Drivetrain, Exhaust System Chassis: Suspension (Front & Rear), Steering System, Braking System, Wheels & Tires Electrical: Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, HVAC Controls, Power Accessories (Windows, Doors, Seats), Antitheft System, SRS (Airbag) System Body: Exterior Body Panels, Interior Trim, Doors, Hood, Tailgate, Glass, Seating Systems, Stow 'n Go (if applicable) HVAC: Air Conditioning, Heating, Ventilation, Climate Control Systems Procedures Included Maintenance: Routine Service (Oil Changes, Filter Replacements), Fluid Checks & Changes, Inspections Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Diagnostics Repair: Component Replacement, Overhaul Procedures, Adjustment Procedures Installation: Component Installation, Accessory Installation (factory/dealer) Rebuild: Engine Rebuilding, Transmission Rebuilding, Differential Rebuilding Technical Depth Depth: Comprehensive: From basic fluid checks to complete engine and transmission overhauls, including electrical schematics and diagnostic procedures. Detail Level: Detailed step-by-step instructions with torque specifications, clearances, and alignment data. Diagrams Visuals: Exploded views, wiring diagrams, diagnostic flowcharts, component illustrations. 📊 Manual Specifications File Format Compatibility: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, 10, 11, macOS) Print Quality Resolution: High-resolution PDF for clear viewing and printing. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) Features Searchability: Searchable text within the PDF for quick information retrieval. Printability: Printable pages for physical reference in the workshop. ⚙️ Engine Specifications Primary Engine Engine Code: EGA (3.3L V6) Displacement: 3.3 Liters (201 cubic inches) Configuration: SOHC V6 Bore X Stroke: 3.83 inches x 3.07 inches (97.3 mm x 78.0 mm) Compression Ratio: 9.6:1 Horsepower: 180 HP @ 5000 RPM (approx.) Torque: 205 lb-ft @ 3600 RPM (approx.) Fuel System Induction: Electronic Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Options Optional Engine: 3.8L V6 (L26) - 205 HP / 240 lb-ft (in some later models within this range) Optional Engine 2: 4.0L V6 (SOHC - PowerTech) - 230 HP / 260 lb-ft (introduced in 2005/2006 models) 🔧 Transmission Standard Type: 4-Speed Automatic Transmission Model: 41TE / 42LE Optional Type: N/A (Manual transmission not offered on these models) Features Shift Modes: Electronically controlled, with a 'Sport' mode for altered shift points. Fluid Specifications Fluid Type: ATF+4 (Automatic Transmission Fluid, Type 9602) Fluid Capacity: Approx. 7.5 quarts (7.1 liters) pan fill 📐 Dimensions Exterior Length: Approx. 199.5 inches Width: Approx. 77.5 inches Height: Approx. 68.9 inches Wheelbase: Approx. 124.2 inches Interior Passenger Volume: Approx. 160-170 cubic feet (varies by configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 37-40 cubic feet Cargo Volume Behind 2Nd Row: Approx. 80-90 cubic feet (with seats removed/folded) Weights Curb Weight: Approx. 4,200 - 4,500 lbs Gross Vehicle Weight Rating: Approx. 5,800 - 6,000 lbs 🛡️ Safety Features Ratings NHTSA Front Impact: Generally good (5-star rating often awarded for driver and front passenger). NHTSA Side Impact: Good (4-star rating often awarded for front and rear passengers). Active Features ABS: Standard Anti-lock Braking System (ABS) on all models. Traction Control: Optional or standard on higher trims, Traction Control System (TCS). Passive Features Airbags: Frontal airbags for driver and front passenger. Optional side curtain airbags (SRS) available on some trims. Seatbelts: Three-point seat belts for all seating positions, with pretensioners for front occupants. Child Anchors: LATCH (Lower Anchors and Tethers for Children) system for child seat installation. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player. Optional premium audio systems with amplifier and subwoofer. Rear-seat entertainment systems available on higher trims. Navigation: Optional factory navigation system was available on select models. Driver Assistance Cruise Control: Standard cruise control. Parking Assistance: Optional rear parking assist sensors. Connectivity Power Ports: 12V power outlets for accessory charging. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult manual for specific recommendations). Air Filter Replacement: Every 15,000-30,000 miles or as needed based on inspection. Spark Plug Replacement: Typically every 60,000-100,000 miles for iridium-tipped plugs. Coolant Flush: Every 30,000-60,000 miles or 2-4 years....
Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, HVAC Controls, Power Accessories (Windows, Doors, Seats), Antitheft System, SRS (Airbag) System
Body:
Exterior Body Panels, Interior Trim, Doors, Hood, Tailgate, Glass, Seating Systems, Stow 'n Go (if applicable)
HVAC:
Air Conditioning, Heating, Ventilation, Climate Control Systems
Generally good (5-star rating often awarded for driver and front passenger).
NHTSA Side Impact:
Good (4-star rating often awarded for front and rear passengers).
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all models.
Traction Control:
Optional or standard on higher trims, Traction Control System (TCS).
Passive Features
Airbags:
Frontal airbags for driver and front passenger. Optional side curtain airbags (SRS) available on some trims.
Seatbelts:
Three-point seat belts for all seating positions, with pretensioners for front occupants.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system for child seat installation.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player. Optional premium audio systems with amplifier and subwoofer. Rear-seat entertainment systems available on higher trims.
Navigation:
Optional factory navigation system was available on select models.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional rear parking assist sensors.
Connectivity
Power Ports:
12V power outlets for accessory charging.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult manual for specific recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Typically every 60,000-100,000 miles for iridium-tipped plugs.
Coolant Flush:
Every 30,000-60,000 miles or 2-4 years.
Fluid Specifications
Engine Oil:
API Service SN or newer, SAE 5W-30 synthetic blend or full synthetic. (Consult manual for exact specification).
Transmission solenoid pack failures, torque converter shudder, and coolant leaks into the transmission cooler lines (leading to transmission failure) are known issues for some models.
Engine:
Rear main seal leaks, oil cooler line leaks (on some engines), and alternator failures can occur.
Suspension:
Worn ball joints, tie rod ends, and control arm bushings are common wear items.
Electrical:
Faulty window regulators, power door lock actuators, and HVAC blower motor resistors are frequent complaints.
Exhaust:
Exhaust manifold cracks (especially on the rear bank of V6 engines) can lead to exhaust leaks and ticking noises.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later DaimlerChrysler).
Model Evolution
Generations:
This period (2001-2006) represents the 'NS' platform generation, a significant update to the original Caravan/Voyager design. Introduced for the 2001 model year.
Key Updates 2001-2006:
Introduction of Stow 'n Go seating (2005), revised exterior styling, improved interior materials, introduction of the 4.0L V6 engine option, and updated safety features.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Consumer Reports:
Varied reliability ratings over the years; specific model year reviews should be consulted. Known for practicality and family-friendly features.
Industry Awards:
Often recognized for its interior flexibility and cargo capacity, particularly with the advent of Stow 'n Go.
Ratings
Jdpowers:
Reliability and quality rankings varied by model year, with some years performing better than others. Consultation of specific year data is recommended.