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DODGE CARAVAN TOWN COUNTRY VOYAGER Workshop Repair Manual 2001-2006

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🏷️ Basic Information Identification Make: Dodge, Chrysler Model: Caravan, Town & Country, Voyager Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Codes Platform: NS (North American minivans) 👋 Introduction...
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Sku: 283601
DODGE CARAVAN TOWN COUNTRY VOYAGER Workshop Repair Manual 2001-2006
🏷️ Basic Information
Identification
Make:
Dodge, Chrysler
Model:
Caravan, Town & Country, Voyager
Model Years Covered:
2001, 2002, 2003, 2004, 2005, 2006
Codes
Platform:
NS (North American minivans)
👋 Introduction
Market Position
Segment:
Full-size Minivan
Target Audience:
Families, commercial use, DIY mechanics
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Montana
Key Features
Versatility:
Flexible seating arrangements, ample cargo space, Stow 'n Go seating (later models)
Powertrain Options:
Reliable V6 engines, focus on torque and towing capability
Sliding Doors:
Power sliding doors and liftgate for convenience
📋 Manual Details
Coverage Areas
Manual Type:
Professional Workshop Service & Repair Manual
Language:
English
Format:
Downloadable
Page Count
Estimated Page Count:
2000+
📖 Manual Coverage
Systems Covered
Engine:
3.3L V6 (EGA), 3.8L V6 (GJM), 2.4L DOHC I4 (EDZ - Limited markets)
Transmission:
41TE (3-speed Automatic), 42LE (4-speed Automatic)
Brakes:
Front Disc, Rear Disc (ABS)
Suspension:
Front Independent MacPherson Struts, Rear Solid Axle with Coil Springs and Trailing Arms
Steering:
Power Assisted Rack and Pinion
Electrical:
Complete wiring diagrams, fuse and relay locations, component testing, diagnostics
Body And Chassis:
Frame, body panels, doors, glass, interior trim, underbody components
HVAC:
Heating, Ventilation, Air Conditioning system diagnosis and repair
Fuel System:
Fuel tank, pump, injectors, pressure regulator, evaporative emissions
Exhaust System:
Catalytic converter, mufflers, pipes, O2 sensors
Cooling System:
Radiator, water pump, thermostat, hoses, fan
Interior:
Seats, seat belts, airbags, dashboard, console, audio systems
Exterior:
Bumpers, grille, lighting, mirrors, sliding doors, liftgate
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs
Engine Repair:
Full engine disassembly, inspection, and reassembly procedures
Transmission Repair:
Transmission removal, installation, internal component replacement, torque converter service
Brake System Repair:
Pad and rotor replacement, caliper overhaul, bleeding procedures
Suspension And Steering Repair:
Strut replacement, ball joint service, tie rod end replacement, power steering pump service
Electrical Diagnostics:
Troubleshooting common electrical faults, sensor testing, module programming
HVAC Service:
Refrigerant charging, component replacement (compressor, evaporator, condenser)
Body And Collision Repair:
Panel replacement, dent repair, rust mitigation, door alignment
Interior Component Repair:
Seat removal, airbag system service, dashboard disassembly
Diagnostic Trouble Codes:
OBD-II diagnostic codes and troubleshooting steps
Timing Belt Or Chain:
For applicable engines, including tensioner and pulley replacement
Fuel Pump Replacement:
Detailed steps for accessing and replacing the fuel pump module
Alternator And Starter Replacement:
Removal and installation procedures for charging system components
Technical Depth
Depth Of Coverage:
Comprehensive: From basic maintenance to complete engine and transmission rebuilds.
Diagnostics:
Advanced diagnostic procedures, including electrical system tracing and sensor data analysis.
Diagrams:
Step-by-step illustrated procedures and detailed wiring diagrams.
Specifications:
Torque specifications, clearances, tolerances, and fluid capacities.
📊 Manual Specifications
File Format
File Type:
Digital Download (Likely PDF)
Print Quality
Image Resolution:
High resolution for clarity of diagrams and text.
Text Searchability:
Searchable text for quick information retrieval.
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine 1:
3.3L V6 (EGA)
Engine 1 Displacement:
3301 cc
Engine 1 Configuration:
V6, SOHC, 12 Valve
Engine 1 Horsepower:
180 hp @ 5000 rpm (approx.)
Engine 1 Torque:
205 lb-ft @ 4000 rpm (approx.)
Engine 2:
3.8L V6 (GJM)
Engine 2 Displacement:
3778 cc
Engine 2 Configuration:
V6, OHV, 12 Valve
Engine 2 Horsepower:
200 hp @ 5000 rpm (approx.)
Engine 2 Torque:
232 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Ignition System:
Distributorless Ignition System (DIS) with coil packs
Performance
Compression Ratio 3.3L:
8.9:1 (approx.)
Compression Ratio 3.8L:
8.4:1 (approx.)
🔧 Transmission
Standard
Transmission Type Standard:
41TE (3-Speed Automatic)
Optional
Transmission Type Optional:
42LE (4-Speed Automatic) - Primarily with 3.8L engine
Features
Transmission Fluid Type:
ATF+4 (Mopar)
Transmission Fluid Capacity:
Approx. 7.0 - 8.0 quarts (6.6 - 7.6 liters) for 41TE/42LE
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
190.5 inches (4839 mm)
Width:
76.7 inches (1948 mm)
Height:
67.4 inches (1712 mm)
Weights
Curb Weight Approx:
4000 - 4400 lbs (1814 - 2000 kg)
Towing Capacity Max:
Up to 3,800 lbs (1724 kg) with proper equipment
Cargo
Max Cargo Volume:
Approx. 140 - 160 cubic feet (3964 - 4531 liters) with rear seats removed
🛡️ Safety Features
Ratings
NHTSA Rollover Rating 2001:
4 out of 5 stars
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all models
Traction Control:
Optional Traction Control System (TCS)
Passive Features
Airbags:
Front airbags (driver and passenger), optional side airbags
Seat Belts:
Three-point seat belts for all seating positions, front seat pretensioners
💡 Technology Features
Infotainment
Audio Systems:
Factory AM/FM/CD players, optional Infinity premium sound systems.
Rear Seat Entertainment:
Optional factory DVD entertainment systems with flip-down screens.
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Optional rear park assist sensors.
Connectivity
Power Outlets:
12V auxiliary power outlets
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Spark Plug Replacement 3.3L:
Approx. 100,000 miles (160,000 km) - Long life plugs
Spark Plug Replacement 3.8L:
Approx. 100,000 miles (160,000 km) - Long life plugs
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic Blend or Full Synthetic
Engine Oil Capacity 3.3L:
4.5 quarts (4.3 liters) with filter
Engine Oil Capacity 3.8L:
4.5 quarts (4.3 liters) with filter
Coolant Type:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Additive Technology) - Orange
Coolant Capacity:
Approx. 11.5 - 12.5 quarts (10.9 - 11.8 liters)
Known Issues
Transmission Problems:
Intermittent shifting issues, solenoid pack failures, torque converter shudder (especially on 42LE).
Power Sliding Doors:
Motor failures, cable binding, switch issues can affect operation.
Heater Core:
Leaking heater cores, especially in models with the auxilliary heater.
Suspension Components:
Wear on control arm bushings, sway bar links, and struts.
Interior Rattles:
Common minivan issue, often related to trim panels and accessory mounts.
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the modern minivan segment with the original Caravan in 1984.
Model Evolution
Generation:
Third Generation (NS) Facelift
Design Changes 2001:
Significant exterior styling update, interior redesign, improved safety features.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Critical Reception:
Consistently ranked as a strong contender in the minivan segment for its practicality and value.
Safety Awards:
Earned good safety ratings from NHTSA and IIHS during its production run.
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