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Dodge Caravan 2001-2007 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, fleet operators, DIY...
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Sku: 372949
Dodge Caravan 2001-2007 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, fleet operators, DIY mechanics
Competitive Analysis
Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Versatility:
Flexible seating configurations, spacious interior, Stow 'n Go seating (later models)
Value Proposition:
Affordable family transportation with a strong emphasis on practicality and cargo capacity
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Repair Service Manual
Scope:
Maintenance, Service, Troubleshooting, Repair
Format
File Format:
PDF Download
Language
Language:
English
📖 Manual Coverage
Systems Covered
Engine:
All engine types, including 2.4L, 3.3L V6, and 3.8L V6
Transmission:
Automatic Transmissions (4-speed)
Drivetrain:
Front-Wheel Drive (FWD)
Suspension Steering:
Front McPherson strut, rear torsion beam axle; power steering system
Brakes:
Front disc, rear drum (standard); ABS system (optional)
Electrical Lighting:
Battery, charging system, ignition, lighting, instruments, power accessories, body control modules
HVAC:
Heating, ventilation, and air conditioning systems
Fuel Exhaust:
Fuel delivery, fuel injection, exhaust system, emissions control
Body Interior:
Exterior body panels, interior trim, seating, doors, liftgate, power sliding doors
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, coolant flush, brake fluid replacement
Repair:
Component replacement (alternator, starter, water pump, etc.), suspension component repair, brake system overhaul
Troubleshooting:
Diagnosis of engine performance, transmission issues, electrical faults, HVAC problems
Specifications:
Torque specifications, fluid capacities, electrical schematics, diagnostic procedures
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major component overhauls and complex diagnostics
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, text-searchable PDF for easy navigation and printing
Printable:
Printable pages for workshop use
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.4L (2429cc) DOHC 16-valve Inline-4 (K24A or similar Chrysler designation)
Engine 2:
3.3L (3301cc) OHV 12-valve V6 (Chrysler EGAN)
Engine 3:
3.8L (3778cc) OHV 12-valve V6 (Chrysler L32)
Performance
Hp 2.4L:
Approximately 150 hp @ 5900 rpm
Torque 2.4L:
Approximately 160 lb-ft @ 4000 rpm
Hp 3.3L:
Approximately 180 hp @ 4850 rpm
Torque 3.3L:
Approximately 205 lb-ft @ 4000 rpm
Hp 3.8L:
Approximately 190 hp @ 4750 rpm
Torque 3.8L:
Approximately 230 lb-ft @ 3400 rpm
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
41TE/AE 4-speed automatic transaxle
Optional
Transmission Options:
None (4-speed automatic standard across most trims)
Features
Transmission Fluid:
ATF+4 (Chrysler Material Standard MS-9602)
Gear Ratios:
Specific ratios detailed within the manual for each engine variant
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
Approximately 193.5 inches (4915 mm)
Width:
Approximately 76.7 inches (1948 mm)
Height:
Approximately 67.7 inches (1720 mm)
Cargo
Cargo Volume Behind 1St Row:
Approx. 150.1 cu ft (4250 L)
Cargo Volume Behind 2Nd Row:
Approx. 93.1 cu ft (2636 L)
Cargo Volume Behind 3Rd Row:
Approx. 31.5 cu ft (892 L)
Weights
Curb Weight:
Varies by engine and trim, typically 3900-4300 lbs
Gross Vehicle Weight Rating:
GVWR varies, typically 5700-6000 lbs
Towing Capacity:
Up to 3800 lbs (with optional towing package and appropriate engine)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-star (driver and passenger) for 2001-2007 models (varies slightly by year/configuration)
NHTSA Side Impact:
4-star (front and rear passenger) for 2001-2007 models (varies slightly by year/configuration)
IIHS Small Overlap Frontal:
Not rated (vehicles predate this specific testing protocol)
Active Features
ABS:
Anti-lock Braking System (standard on most trims, optional on base models)
Traction Control:
Optional on some models, particularly with V6 engines
Passive Features
Airbags:
Front driver and passenger airbags; optional side curtain airbags on later models
Seatbelts:
3-point front and rear seat belts, LATCH child seat anchors
💡 Technology Features
Infotainment
Audio Systems:
Factory AM/FM/CD players; optional premium Infinity sound systems
Rear Seat Entertainment:
Optional rear-seat video entertainment systems available on some trims
Driver Assistance
Cruise Control:
Standard cruise control
Parking Sensors:
Optional rear parking assist sensors
Connectivity
Auxiliary Input:
Not standard; often required aftermarket installation for audio device connectivity
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type (refer to manual for specific recommendations)
Transmission Fluid Change:
Every 30,000-60,000 miles (refer to manual for specific intervals and ATF+4 specification)
Coolant Flush Interval:
Every 30,000-50,000 miles or 3-5 years
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (or 10W-30 depending on climate, consult manual for exact OEM recommendation)
Coolant Type:
Mopar OAT (Organic Acid Technology) Antifreeze/Coolant (or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Transmission Failures:
Some models experienced transmission issues (slipping, harsh shifts), often related to fluid degradation or solenoids. Regular fluid changes are critical.
Power Sliding Doors:
Motor, track, and switch issues can affect the operation of power sliding doors.
Ignition Switch Failure:
Intermittent electrical issues or no-start conditions can be linked to a failing ignition switch.
Heater Core Leaks:
Leaking heater cores can cause coolant loss and a sweet odor inside the cabin.
Climate Control Actuators:
Faulty blend door actuators can cause HVAC temperature control problems.
📚 Vehicle History
Brand Heritage
Dodge History:
Dodge, a division of Chrysler, has a long history of producing practical and durable vehicles, including a significant presence in the minivan market.
Model Evolution
Generation:
Third Generation Dodge Caravan (NS platform, revised for 2001)
Design Changes:
Updated exterior styling, interior refinements, introduction of Stow 'n Go seating for 2005 model year. Enhanced safety features.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; Saltillo, Mexico
Production Years:
Third generation: 1996-2000; Fourth generation (this manual's coverage): 2001-2007
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Mixed ratings over the years, often praised for practicality and space, but with recurring reliability concerns in certain areas (e.g., transmission)
Jd Power Rankings:
Ratings vary by year and model; often positioned as a budget-friendly option in the minivan segment.
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