Target Audience:
DIY enthusiasts, independent repair shops, fleet maintenance
Key Competitors:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture
Design Philosophy:
Versatile, family-oriented minivan with Stow 'n Go seating (introduced later in this generation) and flexible interior configurations.
Manual Purpose:
To provide comprehensive, factory-level repair and maintenance information for the specified Dodge Grand Caravan models.
Engine:
3.3L V6 OHV, 3.8L V6 OHV
Transmission:
4-speed Automatic (41TE/42LE)
Brakes:
Front Disc, Rear Drum (with optional ABS)
Suspension:
Front Independent (MacPherson strut), Rear Torsion Beam
Steering:
Power Rack and Pinion
Electrical:
Complete Wiring Diagrams, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Power Accessories
Body And Chassis:
Body Panels, Doors, Glass, Interior Trim, Frame, Bumpers
HVAC:
Heating, Ventilation, Air Conditioning
Fuel System:
Fuel Delivery, Fuel Tank, Injectors
Exhaust System:
Exhaust Manifolds, Catalytic Converter, Muffler
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Belt Inspection and Replacement, Spark Plug Replacement
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-based Diagnostics, Component Testing
Repair:
Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair
Installation:
Component Replacement (e.g., Alternator, Starter, Water Pump), Accessory Installation
Diagnostics:
OBD-II System, Sensor Testing, Actuator Testing
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds and complex electrical diagnostics)
Engine Option 1:
3.3L (201 ci) OHV V6
Engine Option 2:
3.8L (230 ci) OHV V6
Horsepower 3.3L:
Approx. 180 hp @ 4600 rpm
Torque 3.3L:
Approx. 205 lb-ft @ 3200 rpm
Horsepower 3.8L:
Approx. 205 hp @ 5000 rpm
Torque 3.8L:
Approx. 240 lb-ft @ 3000 rpm
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Ignition Type:
Distributorless Ignition System (DIS) with coil-on-plug or waste spark (depending on year/engine)
NHTSA Frontal Driver:
Good (2002-2004 models)
NHTSA Frontal Passenger:
Good (2002-2004 models)
NHTSA Side Driver:
Acceptable (2002-2004 models)
NHTSA Side Rear Passenger:
Acceptable (2002-2004 models)
ABS:
Available on most models
Airbags:
Driver and front passenger airbags
Seat Belts:
3-point seat belts for all seating positions
Audio System:
Factory AM/FM/CD player, optional premium audio systems, rear seat entertainment options available on higher trims.
Navigation:
Optional factory navigation system (less common for these years).
Cruise Control:
Standard on most trims.
Parking Sensors:
Optional rear parking assist system available.
Remote Keyless Entry:
Available on most trims.
Oil Change Interval:
Every 3,000 - 7,500 miles (5,000 - 12,000 km) or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendations).
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or as needed based on driving. Consult manual for specific procedures.
Coolant Change:
Every 30,000 - 100,000 miles (48,000 - 160,000 km) or 2-5 years, depending on coolant type (HOAT recommended).
Engine Oil Viscosity:
0W-30 (Chrysler specification MS-6395) or 5W-30 (refer to manual for exact application based on temperature)
Coolant Type:
Mopar Antifreeze/Coolant (MS-7170) or equivalent HOAT (Hybrid Organic Additive Technology)
Transmission Slipping:
Common issue with the 41TE/42LE transmissions, often related to internal wear or fluid degradation. Manual provides diagnostics.
Rear Heat Exchanger Leaks:
The heater core for the rear climate control can develop leaks, often presenting as a sweet smell or moisture in the cabin.
Power Sliding Door Issues:
Mechanisms can become stiff or fail, requiring lubrication or component replacement. Manual covers operation and repair.
Climate Control Actuator Failure:
Mode door actuators can fail, leading to incorrect air distribution. Manual provides location and replacement procedures.
Oil Filter Bypass Valve Leaks:
Some filter housings were prone to leaks. Manual details proper seal replacement.
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan/Voyager in the mid-1980s, establishing a dominant market presence.
Generation:
Second Generation (NS), launched for the 1996 model year, with this 2001 facelift (often referred to as '2nd generation facelift' or 'mini-refresh') introducing updated styling and features.
Assembly Locations:
Windsor, Ontario, Canada; Saltillo, Coahuila, Mexico
Konsumen Reports Ratings:
Varies by year, but generally considered a practical and affordable family vehicle, though reliability ratings could be inconsistent compared to Japanese competitors.
Jd Power Dependability:
Historically, minivans in this era often faced challenges in long-term dependability compared to some competitors. Manual is key for proactive maintenance.
Manufacturer Certification:
This manual is designed to align with factory service procedures and specifications.
