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Dodge Caravan 2006 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2006 Generation Generation Name: Fourth Generation (RS) Generation Years: 2001-2007 Codes Platform Code: RS 👋 Introduction Market Position Market Segment: Minivan...
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Dodge Caravan 2006 Factory Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2006
Generation
Generation Name:
Fourth Generation (RS)
Generation Years:
2001-2007
Codes
Platform Code:
RS
👋 Introduction
Market Position
Market Segment:
Minivan / Family Vehicle
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Vehicle Strengths:
Spacious interior, flexible seating, available Stow 'n Go (later generations), proven powertrain options
Manual Value Proposition
Value For Buyers:
Provides comprehensive, OEM-level information for DIY repairs, maintenance, and diagnostics, saving significant costs compared to professional service.
📋 Manual Details
Coverage Areas
All Trims Included:
Yes
Engine Variants Covered:
2.4L 4-Cyl (EDZ), 3.3L V6 (EGH), 3.8L V6 (EWX), 2.5L Diesel, 2.8L Diesel (VM Motori)
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Factory Service Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
2.5L/2.8L Diesel, 2.4L 4-Cyl, 3.3L V6, 3.8L V6: Fuel, Ignition, Cooling, Lubrication, Exhaust, Emission Controls, Starting, Charging
Transmission Systems:
Automatic Transmissions (e.g., 40TE/41TE, 42LE): Service, Diagnosis, Overhaul, Fluid Specifications
Drivetrain Systems:
Front Wheel Drive, Axles, CV Joints, Differential
Suspension Systems:
Front Struts, Rear Shock Absorbers, Springs, Control Arms, Bushings, Alignment Specifications
Steering Systems:
Power Steering System, Steering Column, Tie Rods, Rack and Pinion
Brake Systems:
Front/Rear Disc Brakes, ABS, Parking Brake, Hydraulic System
Electrical Systems:
Battery, Alternator, Starter, Lighting, Fuses, Relays, Wiring Diagrams, Body Control Module (BCM), Powertrain Control Module (PCM)
HVAC Systems:
Air Conditioning, Heating, Ventilation, Climate Control
Body And Interior Systems:
Body Panels, Doors, Windows, Seats, Trim, Security System
Body Electrical:
Interior/Exterior Lighting, Power Accessories (windows, locks, mirrors), Instrument Cluster, Wiper/Washer System, Horn
Procedures Included
Maintenance Procedures:
Oil Change, Filter Replacement, Spark Plug Replacement, Fluid Checks/Changes, Belt Replacement, Brake Pad Replacement
Troubleshooting Procedures:
Diagnostic Trouble Codes (DTCs), Symptom-Based Diagnosis, Electrical Circuit Testing
Repair Procedures:
Engine Overhaul, Transmission Repair, Suspension Component Replacement, Brake Caliper Rebuild, Electrical Component Diagnosis/Replacement
Installation Procedures:
Component Installation, Accessory Installation (where applicable)
Diagnostic Troubleshooting Guides:
Step-by-step troubleshooting trees and flowcharts for common and uncommon problems.
Technical Depth
Diagnostic Depth:
Advanced diagnostics with detailed wiring diagrams and component testing procedures
Rebuild Depth:
Complete engine and transmission overhaul procedures with specifications and torque values
Electrical Schematics:
Comprehensive, component-level wiring diagrams for all systems
Torque Specifications:
Precise torque values for all critical fasteners, engine rebuilds, suspension components, and more.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, searchable, printable pages
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Completeness
Manual Completeness:
Comprehensive, covering all systems and components for the specified model year and engine variants.
⚙️ Engine Specifications
Primary Engine
Engine 2.4L:
2.4L DOHC 4-Cylinder (Code: EDZ), approx. 150 hp @ 5800 rpm, 165 lb-ft torque @ 4000 rpm
Engine 3.3L:
3.3L SOHC V6 (Code: EGH), approx. 180 hp @ 5000 rpm, 205 lb-ft torque @ 3600 rpm
Engine 3.8L:
3.8L SOHC V6 (Code: EWX), approx. 200 hp @ 5000 rpm, 235 lb-ft torque @ 3600 rpm
Engine 2.5L Diesel:
2.5L Turbo Diesel (VM Motori RL420 SOHC), approx. 115 hp, 200 lb-ft torque (performance varies by specific tune)
Engine 2.8L Diesel:
2.8L CRD Turbo Diesel (VM Motori R428 DOHC), approx. 148 hp, 250 lb-ft torque (performance varies by specific tune)
Performance
Compression Ratio 2.4L:
9.4:1
Compression Ratio 3.3L V6:
9.3:1
Compression Ratio 3.8L V6:
9.0:1
Fuel System
Fuel Delivery Gasoline:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (2.4L, 3.3L, 3.8L); Diesel fuel (2.5L, 2.8L)
Diesel Injection System:
Mechanical or Common Rail Diesel Injection (CRD) depending on specific engine
🔧 Transmission
Standard
Standard Transmission:
4-Speed Automatic Transmission (e.g., 40TE/41TE for 2.4L, 42LE for V6)
Optional
Optional Transmission:
Manual Transmission (less common, primarily on base 2.4L models)
Features
Transmission Features:
Electronically controlled, Lock-up torque converter
📐 Dimensions
Exterior
Wheelbase:
119.3 inches
Length:
187.7 inches
Width:
72.0 inches
Height:
67.1 inches
Cargo
Max Cargo Volume:
Approx. 140.5 cubic feet (with rear seats removed)
Weights
Curb Weight Start:
Approx. 3,700 lbs (2.4L)
Curb Weight End:
Approx. 4,200 lbs (3.8L AWD)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4 Stars (Driver & Passenger)
NHTSA Side Impact Rating:
4 Stars (Front), 3 Stars (Rear)
IIHS Rollover Rating:
Acceptable
Active Features
ABS:
Standard on most trims
Traction Control:
Optional
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point seatbelts for all seating positions, driver and front passenger pretensioners
💡 Technology Features
Infotainment
Infotainment Options:
AM/FM stereo with CD player, optional CD/MP3 player, optional rear-seat entertainment system
Driver Assistance
Driver Assistance Features:
Limited for this model year; primarily ABS and optional traction control.
Connectivity
Connectivity Features:
Optional Sirius Satellite Radio, auxiliary audio input (later in the generation)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles, depending on oil type and driving conditions (refer to manual for specifics)
Engine Air Filter Replacement:
Every 15,000-30,000 miles or as needed
Spark Plug Replacement:
30,000 miles (standard plugs) to 100,000 miles (platinum/iridium plugs)
Transmission Fluid Change:
Every 30,000-60,000 miles (consult manual for specific transmission and fluid type)
Fluid Specifications
Engine Oil 2.4L:
SAE 5W-30, API Certified (Capacity: 4.5 quarts with filter)
Engine Oil 3.3L 3.8L:
SAE 5W-30, API Certified (Capacity: 4.5 quarts with filter)
Transmission Fluid:
ATF+4 (Mopar Part Number: 05013457AA or equivalent)
Coolant:
50/50 mixture of Mopar Antifreeze/Coolant (MS-7170) and distilled water
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent meeting MS-5901
Brake Fluid:
DOT 3 or DOT 4 (check specific fill cap)
Known Issues
Common Issues 2.4L:
Head gasket failures, oil leaks, transmission solenoid issues
Common Issues V6:
Intake manifold gasket leaks, power steering pump failure, rear evaporator core leaks (for dual-zone HVAC)
Common Issues General:
Door lock actuator failures, window regulator issues, suspension component wear (ball joints, tie rods)
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan in 1983.
Model Evolution
Fourth Generation Updates:
This generation introduced optional all-wheel drive, improved safety features, and a more refined interior compared to its predecessors.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years:
1984-2007 (for Caravan/Voyager/Town & Country nameplates under Chrysler Corporation)
🏆 Awards & Recognition
Recognitions
Historical Accolades:
Caravan and its siblings have consistently been strong sellers in the minivan segment, often cited for practicality and value.
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