DODGE CARAVAN Service Repair Manual 2001 2002 2003 2004 2005 2006 2007

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Product Name: DODGE CARAVAN Service Repair Manual 2001-2007 Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 Generation Generation: Fourth Generation...

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Sku: 287435

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

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Product Name:

DODGE CARAVAN Service Repair Manual 2001-2007

Model Years Covered:

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

Generation

Generation:

Fourth Generation (RS Body Style)

Codes

Platform Code:

Chrysler RS

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, commercial operators, DIY mechanics.

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza.

Strengths:

Spacious interior, versatile seating configurations, comfortable ride, wide range of engine options, generally affordable pricing.

Key Features

Seating Capacity:

Up to 7 or 8 passengers (depending on configuration).

Cargo Versatility:

Stow 'n Go seating (later models within this range), removable second and third-row seats, ample cargo volume.

Powertrain Availability:

Multiple engine options including V6 powerplants catering to different performance and economy needs.

📋 Manual Details

Coverage Areas

General Coverage:

Complete service and repair for all models and engines of the Dodge Caravan (2001-2007).

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder heads, block, crankshaft, pistons, connecting rods, timing components, lubrication system, cooling system, fuel system (mechanical and electronic), emission control systems.

Engine Performance:

Engine tuning, performance diagnostics, power output analysis, fuel economy optimization.

Transmission Automatic:

4-speed Automatic Transaxle (40TE/41TE), removal, installation, overhaul, internal components, valve body, torque converter, electronic controls, diagnostics.

Transmission Manual:

If applicable (less common for this generation of Caravan), details on manual gearboxes.

Drivetrain:

Front-wheel drive (FWD), drive axles, CV joints, wheel bearings, differential.

Suspension Front:

MacPherson strut system, control arms, ball joints, sway bar, springs, shock absorbers, steering knuckle, alignment specifications.

Suspension Rear:

Independent rear suspension (IRS) with trailing arms and coil springs, shock absorbers, bushings, alignment specifications.

Brakes Front:

Vented disc brakes, caliper, pads, rotors, brake lines, master cylinder, ABS system components.

Brakes Rear:

Solid disc or drum brakes (depending on configuration), caliper/wheel cylinder, pads/shoes, rotors/drums, parking brake system.

Steering:

Power rack and pinion steering, steering column, intermediate shaft, power steering pump, fluid, system diagnostics, alignment.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor, solenoid), ignition system (coils, plugs, wires), wiring diagrams, fuses, relays.

Lighting:

Headlights, taillights, brake lights, turn signals, interior lighting, bulb replacement, headlight aim adjustment.

Instrument Panel Controls:

Gauges, warning lights, indicators, switches, climate controls, infotainment system controls.

HVAC:

Heating, ventilation, air conditioning (HVAC) system, compressor, condenser, evaporator, blower motor, refrigerant, system charging, diagnostics, climate control unit.

Body Exterior:

Body panels, doors, hood, liftgate, bumpers, glass, mirrors, weatherstripping, paint, rust prevention.

Body Interior:

Seating, upholstery, trim panels, carpeting, headliner, cargo area, interior lighting, accessory installation.

Restraint Systems:

Airbag system (SRS), seat belts, pre-tensioners, SRS module diagnostics and replacement.

Power Accessories:

Power windows, power locks, power mirrors, remote keyless entry, power sliding doors (if equipped), power liftgate (if equipped), tailgate glass operation.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, battery maintenance, spark plug replacement, belt replacement.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs).

Repair:

Detailed step-by-step repair instructions for all major components and systems, including component removal, disassembly, inspection, repair, reassembly, and installation.

Diagnostics:

ECM/PCM diagnostic procedures, sensor testing, actuator testing, circuit testing, scan tool usage, wiring diagrams for diagnostic purposes.

Overhaul:

Complete overhaul procedures for engines and transmissions, including detailed component specifications and tolerances.

Calibration Adjustment:

Wheel alignment procedures and specifications, headlight aiming, idle speed adjustments, throttle body cleaning and relearn procedures.

Technical Depth

Depth:

Comprehensive: Covers everything from basic scheduled maintenance and fluid changes to complex engine and transmission overhauls, advanced electrical diagnostics, and body repair.

Diagnostic Capability:

Advanced diagnostic routines, including specific tests for sensors, actuators, and control modules, utilizing scan tools and multimeter testing.

Component Specifications:

Detailed torque specifications, clearances, tolerances, and material specifications for all critical components.

Wiring Diagrams:

Complete and detailed electrical wiring diagrams for all vehicle systems, including power distribution, grounds, and signal paths.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text within the PDF document for quick information retrieval.

Quality:

High-resolution scanned pages ensuring clarity of text, diagrams, and images.

Print Quality

Printability:

Printable pages allowing users to create physical copies of sections or the entire manual.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

3.3L OHV V6 (EGA)

Displacement 1:

3.3 Liters

Horsepower 1:

Approx. 180 HP @ 5000 RPM

Torque 1:

Approx. 210 lb-ft @ 3600 RPM

Engine Option 2:

3.8L OHV V6 (L32)

Displacement 2:

3.8 Liters

Horsepower 2:

Approx. 200-215 HP @ 5200 RPM

Torque 2:

Approx. 230-245 lb-ft @ 4000 RPM

Engine Option 3:

4.0L SOHC V6 (SOHC EER)

Displacement 3:

4.0 Liters

Horsepower 3:

Approx. 230 HP @ 5200 RPM

Torque 3:

Approx. 245 lb-ft @ 4000 RPM

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

Injection Type:

Sequential Multi-port Electronic Fuel Injection (MPI)

Fuel Pump Pressure:

Refer to specific engine section (typically 39-53 PSI)

Fuel Filter Location:

In-tank or inline, model dependent.

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle (40TE/41TE)

Optional

Transmission Type Optional:

N/A for this generation (only automatic)

Features

Torque Converter Lockup:

Torque converter clutch with variable apply for improved efficiency.

Transmission Fluid Type:

ATF+4 (Chrysler Mopar)

Transmission Fluid Capacity:

Approx. 4.0 - 4.5 Quarts (dry fill) / 3.0 - 3.5 Quarts (drain and fill)

📐 Dimensions

Exterior

Wheelbase:

119.3 inches (approx.)

Length:

190.5 - 194.5 inches (approx., depending on sub-model/tailgate)

Width:

74.0 inches (approx.)

Height:

68.9 inches (approx.)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 25.5 - 30 cu ft

Cargo Volume Behind 2Nd Row:

Approx. 77 - 84 cu ft

Cargo Volume Max:

Approx. 140 - 160 cu ft

Weights

Curb Weight:

4,000 - 4,500 lbs (approx., depending on engine and equipment)

Gross Vehicle Weight Rating:

Approx. 5,700 - 5,900 lbs

Wheels Tires

Wheel Bolt Pattern:

5 x 4.5 inches (5x114.3mm)

Tire Sizes Standard:

P215/65R16, P225/60R16 (common, varies by trim)

Wheel Sizes:

16 inch (standard), 17 inch (optional on some trims)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4 Stars (for models tested)

NHTSA Frontal Impact Passenger:

4 Stars (for models tested)

NHTSA Side Impact Front Seat:

5 Stars (for models tested)

NHTSA Side Impact Rear Seat:

4 Stars (for models tested)

IIHS Frontal Offset:

Good (for models tested)

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

Optional Traction Control System (TCS) on some models.

Electronic Stability Control:

Optional Electronic Stability Control (ESC) available on later models.

Passive Features

Airbags Front:

Standard multi-stage driver and front passenger airbags.

Airbags Side:

Optional front-seat side-impact airbags.

Seat Belts:

Three-point seat belts for all seating positions, front seat belt pretensioners.

Child Safety Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Radio Options:

AM/FM stereo with CD player, cassette player (early models), optional premium audio systems, rear-seat entertainment systems.

Navigation:

Optional factory-installed GPS navigation systems available on higher trim levels.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Parking Assist:

Optional rear parking assist sensors on some models.

Connectivity

Remote Keyless Entry:

Standard or optional remote keyless entry system.

Rear Entertainment:

Optional rear-seat DVD player with screens available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-6,000 miles or 3-6 months, depending on oil type and driving conditions (refer to manual for specifics).

Engine Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on inspection.

Cabin Air Filter Replacement:

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

Spark Plug Replacement:

Platinum: 100,000 miles. Copper (less common): 30,000 miles. Refer to engine type.

Transmission Fluid Change:

Every 30,000-60,000 miles or as per severe duty schedule.

Coolant Change:

First change at 100,000 miles, then every 50,000-60,000 miles.

Fluid Specifications

Engine Oil Viscosity:

SAE 5W-30 (most common for all engines).

Engine Oil Specification:

API SN/SP or ILSAC GF-5/GF-6 certified synthetic blend or full synthetic oil.

Coolant Type:

HOAT (Hybrid Organic Acid Technology) Orange or Pink Coolant (Chrysler Mopar OAT).

Power Steering Fluid:

ATF+4 (Chrysler Mopar).

Known Issues

Transmission Hard Shifting:

Common with the 40TE/41TE transmission; often related to solenoid pack failure or valve body issues. Requires diagnostic testing.

Engine Oil Leaks:

Leaking valve cover gaskets, oil pan gaskets, or front crankshaft seals can occur over time.

Suspension Wear:

Worn ball joints, tie rod ends, and strut mounts are common due to vehicle weight and mileage.

Power Sliding Door Mechanism:

Malfunctioning motors, rollers, or cables for power sliding doors can be an issue.

PCM Failure:

Powertrain Control Module (PCM) failures have been reported, leading to various engine and transmission performance issues.

📚 Vehicle History

Brand Heritage

Brand:

Dodge is a historic American automotive brand known for performance vehicles and practical utility vehicles.

Model Evolution

Previous Generation:

Third Generation (1996-2000), also based on the 'mini-van' concept.

Facelift:

Minor styling updates and feature enhancements occurred throughout the 2001-2007 model run, notably the introduction of Stow 'n Go seating and updated infotainment systems.

Production

Manufacturer:

Chrysler Group LLC (now Stellantis)

Assembly Locations:

Windsor Assembly Plant, Ontario, Canada; Saltillo Truck Assembly Plant, Coahuila, Mexico (for some models/years).

🏆 Awards & Recognition

Recognitions

Consumers Digest Best Buy:

The Dodge Grand Caravan (a longer wheelbase version of the Caravan) was often recognized as a Consumer's Digest Best Buy in its class.

Ratings

Kbb Value:

Consistently ranked as a strong value in the used minivan market, known for holding its value well.