Dodge Caravan Grand Caravan Voyager 2000 Service Repair Workshop Manual Pdf

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🏷️ Basic Information Identification Make: Dodge Model: Caravan / Grand Caravan / Voyager Model Years Covered: 2000 Codes Chassis Code: NS (Second Generation Facelift) 👋 Introduction Market Position Market Segment:...

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Taper: Car

Distributeur:

UGS: 499467

Mots clés: 2000 Car Caravan Cars Dodge Grand Caravan Misc Voyager

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan / Grand Caravan / Voyager

Model Years Covered:

Codes

Chassis Code:

NS (Second Generation Facelift)

👋 Introduction

Market Position

Market Segment:

Minivan

Key Competitors 2000:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana

Competitive Analysis

Segment Advantage:

Dodge minivans were known for their flexible seating (Stow 'n Go precursors), versatile interior space, and robust powertrains.

Key Features

Body Styles:

Short Wheelbase (Caravan/Voyager), Long Wheelbase (Grand Caravan/Grand Voyager)

Seating Capacity:

Available in 5, 6, 7, or 8 passenger configurations depending on trim and seating options.

Door Configuration:

Standard rear sliding door

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, repair, diagnostics, and maintenance

Page Count

Estimated Page Count:

1500-2000+

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine:

3.3L V6 (EGA), 3.8L V6 (L32)

Transmission:

41TE (Automatic Transaxle)

Drivetrain:

Front-Wheel Drive (FWD)

Suspension:

Front Independent MacPherson Strut, Rear Twist-Beam Axle with Coil Springs

Brakes:

Front Disc, Rear Drum (Standard), Optional Rear Disc

Steering:

Power Rack and Pinion

Electrical:

Body Control Module (BCM), Powertrain Control Module (PCM), Lighting, Gauges, HVAC Controls, Power Accessories, Audio System, Anti-theft

Body And Chassis:

Frame, Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System

Climate Control:

Manual and Automatic HVAC Systems

Safety Systems:

Airbags (SRS), Seat Belts, ABS (Anti-lock Braking System)

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication

Engine Repair:

Engine disassembly, assembly, cylinder head, pistons, crankshaft, timing system, cooling system, lubrication system

Transmission Repair:

Transmission removal/installation, internal component diagnosis and repair, torque converter service

Brake Repair:

Brake pad/shoe replacement, rotor/drum service, caliper/wheel cylinder rebuild, brake fluid flush

Suspension And Steering Repair:

Strut/shock replacement, ball joint service, tie rod end replacement, power steering pump/rack service

Electrical Diagnostics:

Wiring diagrams, component testing, troubleshooting common electrical faults

Body And Interior Repair:

Panel replacement, glass installation, trim repair, seat repair

Diagnostics And Troubleshooting:

OBD-II diagnostic codes, symptom-based troubleshooting guides

Specifications And Data:

Torque values, clearances, fluid capacities, diagnostic parameters

Technical Depth

Depth:

Factory-level, from routine maintenance to major overhauls and complex diagnostics

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Print Quality

Print Quality:

High-resolution, suitable for printing key sections or the entire manual

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.3L (201 ci) V6 OHV 12-Valve

Engine 1 Code:

Engine 1 Bore X Stroke:

3.58 x 3.14 in (91 x 80 mm)

Engine 1 Compression Ratio:

9.0:1

Engine 1 Horsepower:

158 hp @ 4700 rpm

Engine 1 Torque:

193 lb-ft @ 3300 rpm

Optional Engine

Engine 2:

3.8L (230 ci) V6 OHV 12-Valve

Engine 2 Code:

Engine 2 Bore X Stroke:

3.77 x 3.38 in (96 x 86 mm)

Engine 2 Compression Ratio:

9.1:1

Engine 2 Horsepower:

180 hp @ 4500 rpm

Engine 2 Torque:

235 lb-ft @ 3000 rpm

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane (recommended)

Engine Management

Engine Control Unit (ECU) or Powertrain Control Module (PCM)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transaxle

Transmission Code:

41TE (Ultradrive)

Optional

Optional Transmission:

None specified for 2000 model year

Features

Transmission Features:

Electronically controlled, adaptive shifting, overdrive

Fluid Specifications

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 9602)

📐 Dimensions

Exterior

Wheelbase Swb:

111.8 inches

Wheelbase Lwb:

119.3 inches

Length Swb:

187.8 inches

Length Lwb:

195.3 inches

Width:

72.0 inches

Height:

67.9 inches

Weights

Curb Weight Est Swb:

3,700 - 4,000 lbs

Curb Weight Est Lwb:

4,000 - 4,300 lbs

Towing Capacity Est:

Up to 3,800 lbs (with optional towing package)

Cargo

Max Cargo Volume Swb:

Approx. 110 cu ft (behind front seats)

Max Cargo Volume Lwb:

Approx. 140 cu ft (behind front seats)

Wheels And Tires

Wheelbase Pattern:

5 x 114.3 mm (5 x 4.5 inch)

Standard Tire Size:

P215/65R16

Optional Tire Size:

P225/60R16 (on some higher trims or optional wheels)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4/5 stars (for some configurations, ratings can vary)

NHTSA Front Impact Passenger:

4/5 stars (for some configurations, ratings can vary)

NHTSA Side Impact Front Driver:

5/5 stars (for some configurations, ratings can vary)

NHTSA Side Impact Front Passenger:

5/5 stars (for some configurations, ratings can vary)

NHTSA Side Impact Rear Driver:

4/5 stars (for some configurations, ratings can vary)

NHTSA Side Impact Rear Passenger:

4/5 stars (for some configurations, ratings can vary)

IIHS Front Crash:

Good (for some configurations, ratings can vary)

Active Features

Standard (4-wheel Anti-lock Braking System)

Traction Control:

Optional (TCS)

Passive Features

Airbags:

Driver and front passenger airbags, optional side airbags

Seat Belts:

3-point seat belts for all seating positions, pretensioners for front seats

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player and/or CD player. Optional Infinity or premium sound systems.

Rear Seat Entertainment:

Optional rear-seat video system (VCR or CD-based) available on higher trims.

Driver Assistance

Cruise Control:

Standard on most trims

Parking Assist:

Optional rear park assist sensors available.

Connectivity

Navigation System:

Not commonly available or a very early, primitive system if offered.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 6 months (depending on oil type and driving conditions, consult manual for specifics)

Engine Air Filter Replacement:

Every 15,000-30,000 miles

Cabin Air Filter Replacement:

Every 15,000-30,000 miles (if equipped)

Spark Plug Replacement:

Platinum: 60,000-100,000 miles. Refer to specific plug type.

Transmission Fluid Service:

Every 30,000-60,000 miles (filter and fluid change)

Coolant Flush:

Every 30,000-50,000 miles

Fluid Specifications

Engine Oil Type:

API SN/SP, ILSAC GF-5 or newer, SAE 5W-30 (preferred), SAE 10W-30 also acceptable

Engine Oil Capacity 3.3L:

Approx. 3.8 US quarts (3.6 liters) with filter

Engine Oil Capacity 3.8L:

Approx. 4.2 US quarts (4.0 liters) with filter

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (Pink/Orange)

Coolant Capacity:

Approx. 12.5 US quarts (11.8 liters)

Known Issues

Common Problem 1:

Transmission solenoids and torque converter clutch (TCC) issues leading to slipping or hard shifts.

Common Problem 2:

Power steering pump leaks and noisy pumps.

Common Problem 3:

Heater control valve failures leading to HVAC issues.

Common Problem 4:

Window regulator failures, especially in sliding doors.

Common Problem 5:

Cracked intake manifold (plastic manifold design on some earlier versions, less common on 2000 model year).

Common Problem 6:

CV axle wear and failure.

📚 Vehicle History

Brand Heritage

Brand Focus:

Dodge, a division of Chrysler Corporation, has a long history of producing practical and family-oriented vehicles.

Model Evolution

Generation Codename:

NS (Second Generation Facelift, 1996-2000)

Model Introduction:

The Dodge Caravan and its siblings (Plymouth Voyager, Chrysler Voyager/Town & Country) pioneered the minivan segment in the mid-1980s.

2000 Model Year Updates:

Minor styling tweaks, potential powertrain refinements, updated option packages.

Production

Production Plants:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

Production Years Generation:

1996-2000

🏆 Awards & Recognition

Recognitions

Common Automotive Press Awards:

While the 2000 model year was part of a well-established and popular generation, specific awards for this exact model year are less prominent than initial launch accolades of the generation.

Consumer Reports Ratings:

Often received 'average' to 'below average' reliability ratings in its later years of this generation, particularly concerning transmission and electrical components.

Certifications

Certification:

N/A (Standard vehicle production, not a specialized certification)