DODGE CARAVAN 2001-2007 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Code: RS 👋 Introduction Market Position Positioning: The Dodge Caravan during this generation (2001-2007) was a highly popular minivan, known for its practicality, spacious interior, and versatile seating configurations. It was a staple for families and commercial users alike. Competitive Analysis Competitors: Competed directly with vehicles like the Honda Odyssey, Toyota Sienna, Ford Windstar/Freestar, Chevrolet Venture/Uplander, and the Chrysler Town & Country (sharing platforms). Key Features Vehicle Features: Flexible seating arrangements (Stow 'n Go introduced later in this generation), comfortable ride, ample cargo space, available all-wheel drive (on some models), and a reputation for family utility. Manual Value Proposition Value: This factory service manual is an indispensable tool for owners and technicians seeking to maintain, diagnose, and repair the Dodge Caravan accurately. It provides the definitive factory-level information required for all service tasks. 📋 Manual Details Coverage Areas Geographical Coverage: US/Canada Models Page Count Estimated Page Count: Extensive (specific count not provided, but factory service manuals are typically several thousand pages) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Performance, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Engine Control Systems (ECM/PCM) Transmission Drivetrain: Automatic Transmissions (e.g., 41TE, 42LE), Manual Transmissions (if applicable), Drivetrain Components (CV Joints, Axles, Driveshafts) Suspension Steering: Front Suspension, Rear Suspension, Steering System, Wheel Alignment Brakes: Brake System Components, Hydraulic System, ABS (Anti-lock Braking System), Parking Brake Electrical Electronics: Wiring Diagrams, Fuses and Relays, Lighting System, Instrumentation, Power Accessories, Body Control Module (BCM), Powertrain Control Module (PCM), Diagnostic Trouble Codes (DTCs), Audio System, HVAC Controls Body Interior: Body Panels, Doors, Glass, Seats, Interior Trim, HVAC System (Heating, Ventilation, Air Conditioning), Door Locks, Remote Keyless Entry (RKE) Procedures Included Maintenance Procedures: Scheduled Maintenance, Oil Changes, Fluid Replacements, Filter Replacements, Spark Plug Replacement, Belt Replacement Diagnostic Procedures: Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Scan Tool Usage, DTC Interpretation Repair Procedures: Component Removal and Installation, Overhaul Procedures, Clutch Replacement, Brake Pad/Rotor Replacement, Suspension Component Replacement, Engine Component Repair, Transmission Repair Electrical Troubleshooting: Circuit Diagnosis, Component Testing, Wiring Harness Repair, Connector Inspection Specifications Data: Torque Specifications, Clearances, Fluid Capacities, Electrical Specifications, Diagnostic Values Technical Depth Depth: Comprehensive; covers routine maintenance to major component overhaul and diagnostics. Suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Compatibility: Win95/98/ME/XP/vista/7/8/8.1/10/Linux/MAC/IOS/Android Print Quality Quality: Likely scans of original factory manuals, offering clear diagrams and text. PDF format allows for zooming and printing specific pages. Binding Type Type: Digital (PDF) Paper Type Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Options: Commonly equipped with the 3.3L V6 (EGA) and 3.8L V6 (GPG) engines. Some models may have offered a 2.4L 4-cylinder engine (EDZ) earlier in the production run. Performance 3.3L V6 Horsepower: ~180 hp @ 5000 rpm (Varies slightly by year) 3.3L V6 Torque: ~205 lb-ft @ 3200 rpm (Varies slightly by year) 3.8L V6 Horsepower: ~190-215 hp @ 5000-5200 rpm (Varies by year) 3.8L V6 Torque: ~230-250 lb-ft @ 4000 rpm (Varies by year) Fuel System System: Multi-point Fuel Injection (MPI) Engine Management System: Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on year and engine 🔧 Transmission Standard Type: 4-Speed Automatic Transmission Optional Type: All-Wheel Drive (AWD) available on certain configurations and years. Features Control: Electronic range select (PRNDL) with overdrive. 📐 Dimensions Exterior Wheelbase: Approximately 119.3 inches (for SWB models) Length: Approximately 177.5 inches (SWB) to 195.5 inches (LWB - Grand Caravan) Cargo Cargo Volume Behind 3Rd Row: Varies by configuration, but typically around 15-20 cubic feet for SWB models. Weights Curb Weight: Varies by engine and drivetrain, typically 3900-4500 lbs. 🛡️ Safety Features Ratings NHTSA Front Impact: Good (for 2001-2007 models, varies slightly by specific year and test) IIHS Side Impact: Acceptable to Good (depending on year and specific equipment) Active Features ABS: Standard Anti-lock Braking System (ABS) on most models. Traction Control: Available Traction Control System (TCS) on some models, often coupled with ABS. Passive Features Airbags: Front driver and passenger airbags. Optional side-impact airbags may be available on higher trims. Seat Belts: Three-point seat belts for all seating positions, including lower anchors and tethers for children (LATCH) system. 💡 Technology Features Infotainment Audio System: Factory radio with CD player, AM/FM. Optional premium Infinity sound systems were available. Sirius Satellite Radio was also an option. Rear Entertainment: Optional rear-seat entertainment system with a flip-down screen and wireless headphones available on some higher trims. Driver Assistance Cruise Control: Standard cruise control. Parking Assist: Rear parking assist (ParkSense) was an optional feature on later models. Connectivity Keyless Entry: Remote Keyless Entry (RKE) system was standard or optional depending on trim level. Comfort Convenience Power Accessories: Power...
The Dodge Caravan during this generation (2001-2007) was a highly popular minivan, known for its practicality, spacious interior, and versatile seating configurations. It was a staple for families and commercial users alike.
Competitive Analysis
Competitors:
Competed directly with vehicles like the Honda Odyssey, Toyota Sienna, Ford Windstar/Freestar, Chevrolet Venture/Uplander, and the Chrysler Town & Country (sharing platforms).
Key Features
Vehicle Features:
Flexible seating arrangements (Stow 'n Go introduced later in this generation), comfortable ride, ample cargo space, available all-wheel drive (on some models), and a reputation for family utility.
Manual Value Proposition
Value:
This factory service manual is an indispensable tool for owners and technicians seeking to maintain, diagnose, and repair the Dodge Caravan accurately. It provides the definitive factory-level information required for all service tasks.
📋 Manual Details
Coverage Areas
Geographical Coverage:
US/Canada Models
Page Count
Estimated Page Count:
Extensive (specific count not provided, but factory service manuals are typically several thousand pages)
Comprehensive; covers routine maintenance to major component overhaul and diagnostics. Suitable for professional technicians and advanced DIY enthusiasts.
Likely scans of original factory manuals, offering clear diagrams and text. PDF format allows for zooming and printing specific pages.
Binding Type
Type:
Digital (PDF)
Paper Type
Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Commonly equipped with the 3.3L V6 (EGA) and 3.8L V6 (GPG) engines. Some models may have offered a 2.4L 4-cylinder engine (EDZ) earlier in the production run.
Performance
3.3L V6 Horsepower:
~180 hp @ 5000 rpm (Varies slightly by year)
3.3L V6 Torque:
~205 lb-ft @ 3200 rpm (Varies slightly by year)
3.8L V6 Horsepower:
~190-215 hp @ 5000-5200 rpm (Varies by year)
3.8L V6 Torque:
~230-250 lb-ft @ 4000 rpm (Varies by year)
Fuel System
System:
Multi-point Fuel Injection (MPI)
Engine Management
System:
Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on year and engine
🔧 Transmission
Standard
Type:
4-Speed Automatic Transmission
Optional
Type:
All-Wheel Drive (AWD) available on certain configurations and years.
Features
Control:
Electronic range select (PRNDL) with overdrive.
📐 Dimensions
Exterior
Wheelbase:
Approximately 119.3 inches (for SWB models)
Length:
Approximately 177.5 inches (SWB) to 195.5 inches (LWB - Grand Caravan)
Cargo
Cargo Volume Behind 3Rd Row:
Varies by configuration, but typically around 15-20 cubic feet for SWB models.
Weights
Curb Weight:
Varies by engine and drivetrain, typically 3900-4500 lbs.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Good (for 2001-2007 models, varies slightly by specific year and test)
IIHS Side Impact:
Acceptable to Good (depending on year and specific equipment)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Traction Control:
Available Traction Control System (TCS) on some models, often coupled with ABS.
Passive Features
Airbags:
Front driver and passenger airbags. Optional side-impact airbags may be available on higher trims.
Seat Belts:
Three-point seat belts for all seating positions, including lower anchors and tethers for children (LATCH) system.
💡 Technology Features
Infotainment
Audio System:
Factory radio with CD player, AM/FM. Optional premium Infinity sound systems were available. Sirius Satellite Radio was also an option.
Rear Entertainment:
Optional rear-seat entertainment system with a flip-down screen and wireless headphones available on some higher trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assist:
Rear parking assist (ParkSense) was an optional feature on later models.
Connectivity
Keyless Entry:
Remote Keyless Entry (RKE) system was standard or optional depending on trim level.
Comfort Convenience
Power Accessories:
Power windows, power door locks, and power mirrors were common features, with power sliding doors and a power liftgate available on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles depending on oil type and driving conditions. Refer to manual for specific recommendations.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles, depending on severity of use. Check manual for specific fluid type (e.g., ATF+4).
Spark Plugs:
Intervals vary by plug type, typically 60,000-100,000 miles for platinum or iridium plugs.
Fluid Specifications
Engine Oil:
Typically SAE 5W-30 or 10W-30, meeting Chrysler MS-6395 specification. Always verify with manual.
Coolant:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a 50/50 mix of antifreeze and distilled water.
Transmission Fluid:
Chrysler ATF+4 (MS-9602) is the standard for these transmissions. **Crucial to use the correct fluid to avoid transmission damage.**
Known Issues
Engine Mounts:
Engine mounts can degrade over time, leading to vibration and harshness, particularly during acceleration or braking.
Transmission Issues:
Transmission cooler lines can corrode and leak. Some transmissions may experience shifting issues or solenoid failures with high mileage.
Rear Wiper Motor:
The rear wiper motor is a common failure point.
Power Sliding Doors:
Power sliding door mechanisms can become slow or inoperative due to worn components or electrical issues.
Climate Control:
Blend door actuators for the HVAC system can fail, leading to improper temperature control.
📚 Vehicle History
Brand Heritage
Heritage:
Dodge, as part of Chrysler, has a long history in the automotive industry, with a focus on mainstream vehicles and a strong presence in the minivan segment since its inception.
Model Evolution
Generation:
This manual covers the fourth generation of the Dodge Caravan (and its sibling, the Chrysler Voyager/Town & Country), which ran from 2001 to 2007. This generation saw significant updates in styling, safety, and available features.
Production
Manufacturing Locations:
Primarily manufactured in North America, notably at Chrysler's Windsor Assembly Plant in Ontario, Canada.
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Consistently ranked among the best-selling minivans in North America during its production run.
Safety Awards:
Achieved good safety ratings from organizations like the NHTSA and IIHS for its respective model years, reflecting improvements in structural integrity and safety features.
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