Dodge Caravan 2000-2007 Online Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Codes Chassis Code: RS (Third Generation) Platform: Chrysler RS Platform 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families, individuals needing...

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类型: Car

斯库: 366028

标签: 2000 2001 2002 2003 2004 2005 2006 2007 Car Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Codes

Chassis Code:

RS (Third Generation)

Platform:

Chrysler RS Platform

👋 Introduction

Market Position

Segment:

Mid-size Minivan

Target Audience:

Families, individuals needing versatile cargo and passenger space.

Competitive Analysis

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana SV6.

Key Features

Versatility:

Known for its flexible interior seating (Stow 'n Go introduced later in the generation, but the basic platform offered good space), ample cargo room, and comfortable ride.

Powertrain Options:

Offered a choice of reliable V6 engines providing adequate power for a vehicle of its size and purpose.

Value Proposition:

Often positioned as a more affordable alternative to some competitors while maintaining strong functionality.

📋 Manual Details

Coverage Areas

Model Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Trim Levels Covered:

All available trim levels (e.g., SE, SXT, ES, RT)

Page Count

Estimated Page Count:

2500+

Manual Type

Type:

Factory Authorized Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, potentially HTML)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnosis, repair, and overhaul for all gasoline engines including: 2.4L DOHC (G4HC), 3.3L OHV V6 (EGA), 3.8L OHV V6 (EGH)

Transmission:

Service and repair for automatic transmissions: 4-Speed 41TE/42LE (FWD), including torque converter, valve body, and electronic controls.

Brakes:

Front and rear disc brake systems, ABS (Anti-lock Braking System), parking brake, hydraulic system components, bleeding procedures.

Electrical:

Complete wiring diagrams, component testing, starter, alternator, battery, lighting systems, power windows, power locks, HVAC controls, dashboard instruments.

Suspension Steering:

Front McPherson strut suspension, rear torsion beam axle, power steering system, steering column, wheel alignment specifications.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, compressor, condenser, evaporator, blower motor, climate control module.

Body Interior:

Body panel removal/installation, doors, liftgate, interior trim, seating systems, airbags, seat belts, body sealing.

Procedures Included

Maintenance:

Routine oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad replacement, tire rotations.

Troubleshooting:

Diagnostic flowcharts for common and complex issues, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation and resolution.

Repair:

Step-by-step instructions for engine component repair (e.g., head gasket, timing belt/chain), transmission overhaul, brake caliper replacement, CV joint replacement, fuel pump replacement, alternator replacement.

Diagnostics:

Information on using diagnostic scan tools, interpreting live data, performing component tests, and understanding electronic control module (ECM) functions.

Technical Depth

Depth:

Comprehensive, from basic maintenance to advanced diagnostics and full component rebuilds. Includes specifications, tolerances, and torque values for critical fasteners.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages for physical reference.

Print Quality

Image Quality:

High-resolution images, diagrams, and schematics.

Binding Type

Physical Binding:

N/A (Digital Format)

Paper Type

Physical Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Displacement 1:

2.4 Liters (2429 cc)

Configuration 1:

Inline 4-Cylinder, DOHC

Horsepower 1:

150 hp @ 5900 rpm

Torque 1:

165 lb-ft @ 4500 rpm

Secondary Engine

Engine Code 2:

Displacement 2:

3.3 Liters (3301 cc)

Configuration 2:

V6, OHV, 12 Valves

Horsepower 2:

180 hp @ 5000 rpm

Torque 2:

205 lb-ft @ 4000 rpm

Tertiary Engine

Engine Code 3:

Displacement 3:

3.8 Liters (3778 cc)

Configuration 3:

V6, OHV, 12 Valves

Horsepower 3:

200-215 hp @ 5200-5400 rpm (depending on year/application)

Torque 3:

235-245 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type 1:

4-Speed Automatic (41TE/42LE)

Drive Type:

Front-Wheel Drive (FWD)

Optional

Transmission Type 2:

None (4-speed automatic was standard across most models)

Features

Features:

Electronically controlled, Adaptive transmission logic, Lock-up torque converter.

Fluid Specifications

Transmission Fluid Type:

ATF+4 (MS-9602) or equivalent Dexron III/Mercon

Fluid Capacities

Transmission Fluid Capacity:

Approx. 9.5 - 11.5 quarts (9.0 - 10.9 liters) (check dipstick for accurate level)

📐 Dimensions

Exterior

Length:

Approx. 181.5 - 184.7 inches (4610 - 4691 mm) (depending on configuration)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 67.5 - 68.5 inches (1715 - 1740 mm)

Wheelbase:

Approx. 112.1 inches (2847 mm)

Interior

Passenger Volume:

Approx. 140 - 150 cubic feet (3964 - 4248 liters)

Cargo

Cargo Volume Behind 1St Row:

Approx. 140 - 155 cubic feet (3964 - 4389 liters)

Cargo Volume Behind 2Nd Row:

Approx. 50 - 70 cubic feet (1416 - 1982 liters)

Weights

Curb Weight:

Approx. 3600 - 4100 lbs (1633 - 1860 kg) (depending on engine and options)

Gross Vehicle Weight Rating Gvwr:

Approx. 5300 - 5800 lbs (2404 - 2631 kg)

Towing Capacity:

Up to 3800 lbs (1724 kg) (with optional towing package)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Rating:

Good (for models tested)

NHTSA Frontal Passenger Rating:

Good (for models tested)

IIHS Side Impact Rating:

Acceptable or Good (depending on year and specific testing)

Active Features

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

Available Traction Control System (TCS) on some later models.

Passive Features

Airbags:

Front driver and passenger airbags. Optional side airbags were available on some later models.

Seatbelts:

3-point front and rear seat belts, shoulder belt height adjusters, driver seat belt reminder.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD/Cassette players. Optional Infinity premium audio systems available. Rear entertainment systems (DVD player) introduced on some later models.

Navigation:

Factory navigation systems were an option on higher trim levels in later model years.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Parking Assist:

Rear parking assist sensors were an option on some later models.

Connectivity

Phone Integration:

Limited connectivity options. Bluetooth integration was not standard in this era. Aftermarket solutions are common.

Other Features

Power Features:

Power windows, power door locks, power mirrors, power sliding doors (optional), power liftgate (optional on some later models).

Remote Keyless Entry:

Available remote keyless entry system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6 months, depending on driving conditions and oil type used (consult manual for specific recommendation).

Engine Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000 to 20,000 miles (24,000 to 32,000 km) or annually.

Spark Plug Replacement:

Approx. 60,000 to 100,000 miles (96,000 to 160,000 km) for platinum or iridium plugs (specific interval depends on plug type and engine).

Coolant Flush Replacement:

Every 30,000 to 50,000 miles (48,000 to 80,000 km) or 2-3 years.

Transmission Fluid Change:

Every 30,000 to 60,000 miles (48,000 to 96,000 km) under normal driving conditions. Severe conditions may require more frequent changes.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (preferred for most conditions), SAE 10W-30 or 10W-40 may be acceptable in specific temperature ranges (consult manual).

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) for 2.4L, 4.5 quarts (4.3 liters) for 3.3L, 5.0 quarts (4.7 liters) for 3.8L (with filter change, always verify with dipstick).

Coolant Type:

Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (typically Mopar OAT or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 Brake Fluid.

Known Issues

Common Problems 1:

Transmission problems, particularly with earlier 4-speed automatics (shift solenoid issues, torque converter clutch shudder).

Common Problems 2:

Ignition coil failure, spark plug wire issues (on models with distributor ignition). Power window regulators can fail.

Common Problems 3:

Suspension wear (ball joints, tie rod ends, sway bar links) due to vehicle weight and use.

Common Problems 4:

EGR valve clogging, especially with the 3.3L and 3.8L engines, leading to rough idle or stalling.

Common Problems 5:

Climate control module failures, leading to HVAC system malfunctions.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge, a division of Chrysler (now Stellantis), has a long history of producing reliable and practical vehicles, including their pioneering minivan offerings.

Model Evolution

Generation:

This period covers the third generation (RS) of the Dodge Caravan, launched in 1996 and significantly updated for the 2001 model year (often referred to as a mid-cycle refresh for the third generation).

Key Updates 2001:

Revised exterior styling, updated interior design, introduction of more powerful engine options, improved safety features, and enhancement of minivan technologies.

Production

Manufacturing Locations:

Primarily built in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

Sales Context:

The Dodge Caravan, along with its Chrysler Town & Country and Plymouth Voyager siblings, were best-selling minivans for much of their production run, defining the segment.

🏆 Awards & Recognition

Recognitions

Consumer Reports:

Varied ratings over the years; generally praised for practicality and value but sometimes criticized for reliability in specific areas.

Jd Power:

Typically received average to above-average ratings for initial quality and dependability in its class during its production run.

Certifications

Safety Certifications:

Met all federal motor vehicle safety standards (FMVSS) in place for the respective model years.