🏷️ Basic Information

Make:

Dodge

Model:

Caravan / Voyager

Production Years Covered:

2002, 2003, 2004, 2005, 2006, 2007

Platform:

Chrysler RS (minivan)

Model Variants Covered:

Dodge Caravan, Dodge Grand Caravan, Plymouth Voyager, Chrysler Voyager (in markets where branded as such).

Chassis Code:

RS

👋 Introduction

Target Audience:

Automotive repair shops, dealerships, fleet maintenance facilities, and experienced DIY vehicle owners.

Competitive Landscape:

Competed directly with other minivans of the era such as the Honda Odyssey, Toyota Sienna, Ford Windstar, and Chevrolet Venture/Venture.

Value Proposition:

Provides comprehensive, authoritative technical data necessary for accurate diagnosis and repair, potentially saving significant labor costs and ensuring proper vehicle maintenance. Addresses the need for reliable information across multiple model years and specified engines.

Manual Benefits:

Enables informed decision-making for repairs, facilitates efficient troubleshooting, and empowers users with knowledge to maintain their vehicles optimally. The split coverage for 2002 vs. 2003-2007 acknowledges potential mid-cycle updates.

📋 Manual Details

Manual Coverage Scope:

Comprehensive workshop repair and service information for 2002-2007 Dodge Caravan and Voyager models.

2002 Specific Coverage:

Includes 'Cooling-2.5L Turbo Diesel' and 'Emission control 2.5L Turbo Diesel', indicating dedicated sections for the diesel variant specific to the 2002 model year. Other sections like 'Introduction & maintenance' are also present.

2003-2007 Specific Coverage:

Lists sections like 'Audio/video', 'Clock', 'Navigation/telecommunication' which may reflect updated features or better integration of these systems in later model years. 'Lubrication & maintenance' replaces 'Introduction & maintenance'.

Estimated Page Count:

Extensive (precise count not provided, but covers numerous systems).

Manual Classification:

Workshop Repair Manual / Service Manual

Language Of Manual:

English

File Format:

PDF

📖 Manual Coverage

All Systems:

Engine (Gasoline and Diesel), Transmission (Automatic), Driveline, Suspension, Brakes, Steering, Cooling, Fuel System, Exhaust System, Electrical Systems, Bodywork, HVAC, Restraints, Audio, Instrumentation, Powertrain Control Modules, Emission Controls.

Electrical System Coverage:

Extensive coverage of the vehicle's electrical system, including wiring diagrams for all major components, fuse box locations, relay assignments, diagnostic procedures for power distribution, lighting systems, instrument cluster, audio, comfort features (HVAC), security systems, and engine/transmission control modules.

Driver Information Systems:

Instrument cluster operation, indicator lights, warning messages, trip computer functions, and diagnostic message systems are covered in detail.

Comfort And Convenience:

Heating and Air Conditioning (HVAC) system diagnostics, component replacement (compressor, evaporator, heater core), refrigerant handling procedures, power door locks, power windows, power seats, cruise control, and wiper/washer systems.

Security And Theft:

Vehicle theft security systems, immobilizer operations, alarm system diagnostics, key fob programming, and central locking system troubleshooting.

Restraint Systems:

Airbag system diagnostics, sensor locations, pretensioner operation, occupant detection systems, and proper handling of airbag components during repair.

Repair And Maintenance Procedures:

Detailed step-by-step repair instructions, diagnostic procedures, troubleshooting guides, maintenance schedules, fluid specifications, torque specifications, component replacement, system adjustments, electrical wiring diagrams, and more.

Engine Repair Procedures:

Covers engine overhaul, cylinder head removal and installation, piston and connecting rod service, crankshaft and bearing replacement, valve train service, timing component replacement, cooling system maintenance and repair, fuel system diagnostics and component replacement, lubrication system service, and engine control system diagnostics.

Diagnostic Trouble Codes:

The manual would provide a comprehensive list of Diagnostic Trouble Codes (DTCs) for the Powertrain Control Module (PCM) and other relevant control modules, along with their definitions and diagnostic flowcharts for troubleshooting.

Level Of Detail:

Professional level, suitable for experienced mechanics and knowledgeable DIY enthusiasts. Covers detailed diagnostics, component-level repairs, and system overhauls.

Chassis And Body Repair:

Detailed information on suspension component replacement (shocks, struts, control arms, ball joints, tie rods), brake system overhaul (pads, rotors, calipers, lines), steering system repair (rack and pinion, power steering pump), wheel bearing replacement, exhaust system repair, bumper and body panel replacement, door and window mechanisms, and interior trim removal.

📊 Manual Specifications

PDF Quality And Features:

High-quality PDF format, compatible with Adobe Reader, searchable text for efficient information retrieval, printable pages.

Digital Print Quality:

Digital; content is clear and legible for printing.

Binding Method:

Digital (PDF).

Digital Paper Equivalent:

Digital document; no physical paper type.

⚙️ Engine Specifications

Engine Options Gasoline:

3.3L V6 (2002-2007), 3.8L V6 (2002-2007), 2.4L DOHC I4 (2002-2007).

2.4L DOHc I4:

Engine Code: EDZ. Displacement: 2.4 Liters (2378cc). Bore x Stroke: 87.5 mm x 99 mm. Compression Ratio: 9.5:1. Horsepower: Approx. 150 hp @ 5200 rpm. Torque: Approx. 165 lb-ft @ 4000 rpm.

3.3L V6:

Engine Code: EHD. Displacement: 3.3 Liters (3301cc). Bore x Stroke: 93 mm x 81 mm. Compression Ratio: 9.3:1. Horsepower: Approx. 180-185 hp @ 5000-5200 rpm. Torque: Approx. 200-205 lb-ft @ 3600-3800 rpm.

3.8L V6:

Engine Code: EGY. Displacement: 3.8 Liters (3778cc). Bore x Stroke: 96 mm x 87 mm. Compression Ratio: 8.5:1. Horsepower: Approx. 200-215 hp @ 5000-5200 rpm. Torque: Approx. 230-235 lb-ft @ 3800-4000 rpm.

Engine Options Diesel:

2.5L Turbo Diesel (specific to 2002 model).

2.5L Turbo Diesel:

Engine Code: EXK (likely). Displacement: 2.5 Liters. Configuration: Inline 4-cylinder, turbocharged. Power/Torque: Significantly lower horsepower than gasoline V6s, but higher torque suited for towing/hauling. Specific figures vary by tune but typically under 120 hp and over 200 lb-ft torque. Likely a JTD or similar indirect injection diesel engine.

Power And Torque Ranges:

Varies by engine. For example, the 3.3L V6 typically produced around 180-185 hp and 200-205 lb-ft torque, while the 3.8L V6 offered slightly more power, around 200-215 hp and 230-235 lb-ft torque. The 2.4L I4 offered approximately 150 hp and 165 lb-ft torque. Diesel figures would be lower in HP but higher in torque, typical for its class.

Torque Characteristics:

The V6 engines, particularly the 3.8L, were known for providing strong low-end torque, which is beneficial for a vehicle of this size and intended purpose (hauling passengers and cargo).

Fuel Delivery And Management:

Electronic Fuel Injection (EFI) for gasoline engines. Diesel likely uses a Bosch-type injection system or similar common rail/direct injection depending on exact specification. Features include multi-point fuel injection, ignition timing control, and emission monitoring systems.

🔧 Transmission

Transmission Types:

Primarily Automatic Transmissions. Common transmissions include the 4-speed 41TE, 42LE, and potentially a 6-speed automatic in later models or specific trims (though less common for this generation). The manual lists 'Automatic transmission' and specifies it for 2003-2007.

Manual Transmission Availability:

Manual transmission was generally not offered or was extremely rare on this generation of Caravan/Voyager in most markets. The manual primarily focuses on automatic transmissions.

Transmission Control And Diagnostics:

Includes procedures for checking fluid levels, filter changes, transmission control module (TCM) diagnostics, solenoid testing, and general rebuild information. Specific diagnostic trouble codes (DTCs) related to transmission performance are likely covered.

41Te/42Le Automatic Transmission:

A common front-wheel-drive automatic transaxle. Features a planetary gearset for forward gears and a torque converter. Known for its robustness but can be prone to solenoid issues and wear on clutch packs if maintenance is neglected.

📐 Dimensions

Wheelbase And Length:

Wheelbase typically around 119.3 inches. Overall length around 190-195 inches depending on specific configuration (e.g., long wheelbase Grand Caravan/Voyager).

Seating Capacity:

Typically offered in 7-passenger configurations with multiple seating arrangements (e.g., Stow 'n Go or traditional captain's chairs and bench seats).

Cargo Volume:

Significant cargo volume, especially with rear seats folded or removed. Specific cubic feet figures vary by configuration but are a key selling point for minivans.

Curb Weight And Gvwr:

Curb weight generally ranging from 4,000 to 4,500 lbs, with Gross Vehicle Weight Rating (GVWR) around 5,500 to 6,000 lbs depending on engine and configuration.

🛡️ Safety Features

Crash Test Performance:

NHTSA and IIHS ratings for this period would be available, generally showing good frontal and side impact protection for the era. Specific ratings would depend on the year and exact configuration.

Braking And Stability Systems:

Anti-lock Braking System (ABS) standard on most models. Traction Control (TCS) available on some models, especially those with higher engine output. Electronic Stability Program (ESP) or similar became more prevalent in later years of this generation.

Restraint Systems:

Front airbags, side curtain airbags (often optional or standard on higher trims), three-point seatbelts with pretensioners for all occupants, and LATCH child seat anchor systems.

💡 Technology Features

Audio And Entertainment Systems:

Standard AM/FM/CD players. Optional upgrades included cassette players, CD changers, premium audio systems (e.g., Infinity), rear-seat entertainment systems (DVD players), and navigation systems on higher trim levels.

Advanced Features:

Cruise control standard. Optional features might include rear parking assist sensors, and basic trip computers. The era predates widespread advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.

Communication Systems:

Some later models may have offered Bluetooth hands-free calling or Uconnect systems, though this was less common across the entire 2002-2007 range compared to later generations.

🔧 Maintenance

Recommended Maintenance Schedule:

Typical intervals include: Oil and filter change every 3,000-7,500 miles depending on oil type used. Air filter replacement every 15,000-30,000 miles. Spark plugs every 60,000-100,000 miles depending on type. Coolant flush every 30,000-60,000 miles. Transmission fluid service every 30,000-60,000 miles. Timing belt/chain service depends on engine (V6 engines typically use chains, 4-cyl might use belts or chains). Brake fluid flush every 2-3 years.

Engine Oil And Coolant:

Engine Oil: SAE 5W-30 (most common for V6 and I4 engines, always confirm with owner's manual or specific engine spec). Coolant: Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a pink or orange color. Transmission Fluid: ATF+4 (Automatic Transmission Fluid) for most automatic transmissions. Power Steering Fluid: ATF+4 or specific Mopar power steering fluid. Brake Fluid: DOT 3.

Transmission Fluid Capacity:

Automatic transmission fluid capacity typically ranges from 4.5 to 6 quarts for a fluid and filter change, with a total capacity of around 8-10 quarts. Always verify specific capacity for the installed transmission model.

Engine Oil Capacity:

Engine oil capacity varies by engine: 2.4L I4 approx. 4.5 quarts, 3.3L V6 approx. 3.75 quarts, 3.8L V6 approx. 3.75 quarts. Always confirm with the dipstick and manual.

Common Wear And Tear Problems:

Transmission solenoid failures (especially in 41TE/42LE transmissions), power window motor failures, rear liftgate actuator issues, HVAC blower motor resistor failure, suspension component wear (ball joints, tie rods), exhaust system rust/leaks, and occasional engine sensor issues (e.g., crankshaft position sensor, camshaft position sensor). For the 2.5L Turbo Diesel, glow plug system and turbocharger maintenance are specific concerns.

Specific Diesel Concerns:

For the 2.5L Turbo Diesel, common issues might include injector pump reliability, turbocharger seal wear, glow plug system failures, and potential intake manifold issues if carbon buildup is severe.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge, alongside Plymouth, pioneered the modern minivan segment with the original Caravan/Voyager in the mid-1980s, establishing a dominant market presence for decades.

Fourth Generation Platform:

This generation (2001-2007) represents the fourth generation of the Dodge Caravan and Plymouth Voyager (later Chrysler Voyager). It introduced significant styling and feature updates, including improved aerodynamics and the introduction of the Stow 'n Go seating system in later years.

Internal Code Designations:

While the platform is RS, internal Chrysler codes for engines and transmissions (e.g., '41TE') are critical for precise identification and repair.

Manufacturing Locations:

Primarily manufactured in Canada (Windsor, Ontario) and the United States (St. Louis, Missouri).

🏆 Awards & Recognition

Industry Accolades:

The Dodge Caravan and its platform siblings have historically been well-regarded in the minivan segment, often cited for practicality, cargo space, and versatility. While specific awards for the 2002-2007 generation might vary, the model line consistently performed well in customer satisfaction and segment sales for its time.