🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Generation:

Fourth Generation (RS)

Platform Code:

RS

Vin Code:

4 - Represents the 4th generation

👋 Introduction

Positioning:

The Dodge Caravan was a highly successful and popular minivan, known for its practicality, versatility, and affordability. It was a staple for families and commercial users alike, offering ample interior space and a comfortable ride.

Competitors:

Key competitors during this period included the Chrysler Town & Country, Plymouth Voyager (also part of the DaimlerChrysler family), Honda Odyssey, Toyota Sienna, and Ford Windstar.

Vehicle Features:

Flexible seating arrangements, sliding rear doors, optional all-wheel drive (on some models/years), and a robust chassis.

📋 Manual Details

Years Covered:

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

Estimated Page Count:

Over 2000 pages (typical for factory service manuals of this era)

Type:

Factory Service Repair Manual

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, diagnosis, disassembly, assembly, timing, cooling, lubrication, fuel delivery, emissions control.

Engine Performance:

Ignition system, fuel injection system (MPI), sensor data, ECM (Engine Control Module) operation, troubleshooting ignition and fuel issues.

Transmission Manual:

Manual transmission service, clutch operation, gearbox overhaul, shift mechanism.

Transmission Automatic:

Automatic transmission service (e.g., 40TE/41TE), torque converter, valve body, internal components, fluid service, diagnostic procedures.

Drivetrain:

Front-wheel drive system, axles, CV joints, differential.

Brakes:

Front and rear brake systems (disc/drum configurations), ABS (Anti-lock Braking System) components, hydraulic systems, parking brake, rotor and pad replacement.

Suspension:

Front independent suspension (MacPherson struts), rear torsion beam axle or independent suspension (depending on configuration), springs, shocks, control arms, bushings, alignment procedures.

Steering:

Power steering system, steering column, steering gear/rack and pinion, tie rods, troubleshooting steering issues.

Body Frame:

Body panel removal and installation, door mechanisms, latches, hinges, glass replacement, structural repairs, rust prevention and repair.

Electrical System:

Wiring diagrams, battery, alternator, starter, lighting systems (headlights, taillights, interior), fuses, relays, power distribution.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant service, compressor, condenser, evaporator, blower motor, climate control modules.

Interior:

Seating systems (including Stow 'n Go if applicable for later years), interior trim, dashboard, instrument cluster, airbags, seat belts.

Diagnostics Troubleshooting:

Diagnostic Trouble Codes (DTCs) and their meanings, symptom-based troubleshooting guides, diagnostic connector (OBD-II) information.

Maintenance:

Oil change procedures, filter replacement (oil, air, fuel, cabin), spark plug replacement, fluid level checks and top-offs, brake fluid flush, coolant system flush.

Repair Overhaul:

Complete engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement (struts, ball joints, tie rods), exhaust system repairs.

Electrical Diagnostics:

Component testing (e.g., alternator output, starter draw), wiring harness continuity testing, diagnostic tool usage.

Troubleshooting Guides:

Step-by-step diagnostic flowcharts for common drivability, electrical, and mechanical issues.

Specifications Tolerances:

Torque specifications for all fasteners, engine clearances, alignment angles, brake runout, tire pressures.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including power distribution, grounds, and circuit tracing.

Specifications Data:

Technical specifications for all components, including dimensions, resistance values, voltage readings, and flow rates.

Depth:

Comprehensive (from routine maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork).

📊 Manual Specifications

Format Details:

Searchable PDF, allowing for quick access to specific topics and procedures.

Quality:

High-resolution, with clear and legible text and detailed illustrations/diagrams.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Options:

2.4L I4 (EDZ), 3.3L V6 (EGA), 3.8L V6 (EWG/ESL)

Engine 2 4L I4 Specs:

Displacement: 2.4 Liters (148 cu in), Horsepower: ~150 hp, Torque: ~170 lb-ft, Configuration: Inline-4, SOHC.

Engine 3 3L V6 Specs:

Displacement: 3.3 Liters (203 cu in), Horsepower: ~180 hp, Torque: ~205 lb-ft, Configuration: V6, OHV.

Engine 3 8L V6 Specs:

Displacement: 3.8 Liters (230 cu in), Horsepower: ~200-215 hp, Torque: ~230-240 lb-ft, Configuration: V6, OHV.

Fuel Type:

Unleaded Gasoline

Injection Type:

Multi-Point Fuel Injection (MPI)

Engine Control Module:

Chrysler's proprietary Engine Control Module (ECM) or Powertrain Control Module (PCM).

🔧 Transmission

Standard Transmission:

4-speed automatic transmission (e.g., 40TE/41TE) was standard on most models.

Optional Transmission:

A 5-speed manual transmission was available on some base models or specific engine configurations, though less common.

Automatic Transmission Features:

Electronically controlled, overdrive capabilities, torque converter lock-up.

Automatic Transmission Fluid:

Chrysler ATF+4 (or equivalent specification, refer to manual for exact PN like 05010886AA)

📐 Dimensions

Length:

Approximately 179.9 inches (standard wheelbase) to 196.3 inches (long wheelbase).

Width:

Approximately 72.0 inches.

Height:

Approximately 66.8 inches.

Passenger Capacity:

Typically 7 passengers across three rows.

Cargo Volume:

Significant cargo space, expandable with folding or removable seats. Varies by wheelbase and configuration, often exceeding 100 cubic feet with seats folded.

Curb Weight:

Ranges from approximately 3,600 lbs to 4,200 lbs depending on engine and configuration.

🛡️ Safety Features

NHTSA Ratings:

Frontal crash test ratings varied by year and test, generally receiving 4 stars for the driver and front passenger in frontal impacts (NHTSA).

Active Safety:

Anti-lock Braking System (ABS) available on most models, traction control (on some later models/trims).

Passive Safety:

Driver and front passenger airbags, side-impact airbags (optional on some models), three-point seat belts for all occupants, reinforced side-impact door beams.

💡 Technology Features

Infotainment Systems:

Base models typically featured a basic AM/FM stereo with cassette and CD player. Higher trims offered upgraded audio systems, optional rear-seat entertainment systems (DVD players), and in-dash CD changers.

Driver Assistance Features:

Limited by modern standards. Features like ABS and traction control were the primary advanced driver aids. Cruise control was common.

Connectivity Features:

Basic connectivity, primarily through audio system inputs. Some later models might have offered auxiliary audio inputs.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions (refer to manual for specific recommendations based on oil type used).

Air Filter Replacement:

Every 12,000-15,000 miles or as needed based on inspection, more frequently in dusty conditions.

Spark Plug Replacement:

Varies by plug type; typically 30,000-100,000 miles for platinum or iridium plugs. Check manual for exact recommendations.

Transmission Fluid Change:

Typically every 30,000-60,000 miles, depending on driving habits and manufacturer recommendations.

Engine Oil Type:

Refer to manual; typically SAE 5W-30 or 5W-40 for V6 engines, and SAE 5W-30 for the 2.4L I4. Always confirm with manual or oil cap.

Coolant Type:

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

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (check manual for specific requirement).

Common Problems:

Transmission solenoid/valve body issues (especially on earlier models), power steering pump leaks, EGR valve issues, rear axle bearing wear, dashboard heater core leaks, window regulator failures, and HVAC blower motor issues.

📚 Vehicle History

Dodge Heritage:

Dodge, as a division of Chrysler Corporation (later DaimlerChrysler), has a long history of producing reliable and practical vehicles, often targeting value-conscious consumers.

Caravan Evolution:

The Dodge Caravan, along with its Chrysler and Plymouth siblings, pioneered the minivan segment in the mid-1980s. The 2000-2007 models represent the fourth generation (RS), which saw significant updates in styling, interior features, and safety compared to earlier generations. This generation introduced features like the Stow 'n Go seating system (in later years of this generation) and improved powertrain options.

Production Period:

Dodge Caravan production spanned multiple generations from 1984 through 2020. The 2000-2007 model years fall within the fourth generation.

Manufacturing Locations:

Primarily produced in North America, with key assembly plants including Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

🏆 Awards & Recognition

Initial Launch Awards:

While specific awards for the 2000-2007 models are less prominent in public recall, the Dodge Caravan nameplate consistently received accolades for practicality and value in its earlier generations. It was a perennial best-seller and a benchmark in the minivan segment.

Consumer Ratings:

Consumer satisfaction and reliability ratings from sources like Consumer Reports varied across model years and engine configurations, with some years and powertrains being more robust than others. The manual provides insights into common wear items and potential fixes for these issues.