🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Generation:

Fourth Generation (RS)

Platform Code:

RS

👋 Introduction

Segment:

Full-size Minivan

Target Audience:

DIY mechanics, automotive repair shops, fleet maintenance personnel, and owners seeking to understand their vehicle's systems.

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza, Chrysler Town & Country/Voyager

Value Proposition:

Provides OEM-level technical information for diagnosing, maintaining, and repairing the Dodge Caravan across a significant portion of its fourth-generation lifecycle, enabling cost savings and empowering vehicle owners.

📋 Manual Details

Model Years:

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

Body Styles:

All body styles (e.g., Standard Wheelbase, Extended Wheelbase/Grand Caravan)

Estimated Pages:

1500+

Type:

Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical (3.3L V6, 3.8L V6, 4.0L V6), Fuel system, Exhaust system, Ignition system, Cooling system, Lubrication system, Engine control systems (PCM, sensors, actuators), Automatic transmission (4-speed: 41TE, 42LE, 45RFE)

Chassis:

Front suspension, Rear suspension (multi-link beam axle), Steering system (power rack and pinion), Brake system (ABS, disc/drum configurations), Wheels and tires

Body And Interior:

Body panels, Doors, Liftgate, Sliding doors, Seats, Interior trim, HVAC system, Power accessories (windows, locks, mirrors), Wiper system, Lighting system, Exterior trim

Electrical And Electronics:

Wiring diagrams, Fuses and relays, Battery, Charging system (alternator), Starting system, Instrument cluster, Audio system, Powertrain control module (PCM), Body control module (BCM), Antitheft system, Power sliding door module, Remote keyless entry

Maintenance:

Oil change, Filter replacement, Fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), Spark plug replacement, Air filter replacement, Belt replacement, Wiper blade replacement

Diagnostics And Troubleshooting:

OBD-II diagnostic codes (DTCs), Symptom-based troubleshooting, Diagnostic connector pinouts, Component testing (sensors, actuators, relays), Scan tool procedures

Repair And Rebuild:

Engine repair (head gaskets, timing components, internal seals), Transmission overhaul, Brake caliper and rotor replacement, Suspension component replacement (ball joints, tie rod ends, struts, shocks), Steering rack replacement, HVAC component replacement (compressor, evaporator), Power sliding door mechanism repair

Installation And Adjustment:

Accessory installation, Component alignment, Brake bleeding, Clutch adjustment (if applicable, though unlikely for this era Caravan), Suspension alignment specifications

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

Compatibility:

Compatible with all PDF readers on Windows, Mac, Linux, iOS, and Android devices.

Quality:

High-resolution scans, clear text, legible diagrams and illustrations.

Type:

N/A (Digital Format)

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine 1:

3.3L V6 OHV (EGA)

Engine 1 Displacement:

3301 cc (201.5 cubic inches)

Engine 1 Power:

Approx. 180-185 hp @ 5000-5200 rpm

Engine 1 Torque:

Approx. 210-220 lb-ft @ 3200-3400 rpm

Engine 2:

3.8L V6 OHV (L32)

Engine 2 Displacement:

3778 cc (230.5 cubic inches)

Engine 2 Power:

Approx. 193-205 hp @ 4600-5000 rpm

Engine 2 Torque:

Approx. 230-250 lb-ft @ 3200-3600 rpm

Engine 3:

4.0L V6 SOHC (ERG - Chrysler)

Engine 3 Displacement:

3952 cc (241.2 cubic inches)

Engine 3 Power:

Approx. 200-205 hp @ 5000 rpm

Engine 3 Torque:

Approx. 260-265 lb-ft @ 3200-3600 rpm

Type:

Electronic Multi-port Fuel Injection (MPI)

Type:

Distributorless Ignition System (DIS) with coil-on-plug or coil packs

🔧 Transmission

Type Std 3.3 3.8:

4-speed Automatic (41TE / 42LE)

Type Std 4.0:

4-speed Automatic (45RFE)

Overdrive Gears:

3rd and 4th gears

Fluid Spec 41Te 42Le:

ATF+4 (MS-9602)

Fluid Spec 45Rfe:

ATF+4 (MS-9602)

📐 Dimensions

Wheelbase Std:

112.1 inches (2847 mm)

Wheelbase Ext:

119.3 inches (3030 mm) - Grand Caravan

Length Std:

176.5 inches (4483 mm)

Length Ext:

183.7 inches (4666 mm) - Grand Caravan

Seating Capacity:

7 passengers (2-2-3 or 2-3-2 configurations)

Cargo Volume Behind 3Rd Row Std:

Approx. 26.5 cu ft (750 liters)

Cargo Volume Behind 3Rd Row Ext:

Approx. 30.5 cu ft (864 liters)

Curb Weight Est Min:

4,000 lbs (1814 kg)

Gross Vehicle Weight Rating Est:

5,600 lbs (2540 kg)

🛡️ Safety Features

NHTSA Frontal Impact Driver:

Four Stars (for specific model years/configurations)

NHTSA Frontal Impact Passenger:

Four Stars (for specific model years/configurations)

IIHS Side Impact:

Acceptable (depending on year and specific equipment)

ABS:

Standard on most trims; Anti-lock Braking System

Traction Control:

Optional or standard on higher trims (TCS)

Electronic Stability Control:

Available on later models (ESC/ESP)

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front-seat side airbags, optional roof-rail airbags on some models

Seatbelts:

3-point seatbelts for all seating positions, pre-tensioners for front seats

💡 Technology Features

Audio System:

AM/FM stereo with CD player, optional cassette, and premium Infinity speaker systems available.

Navigation:

Optional factory navigation system available on higher trims in later model years.

Parking Sensors:

Optional rear park assist system.

Remote Keyless Entry:

Standard on most trims, optional. Power sliding door remote functionality.

Power Sliding Doors:

Key feature, available with remote operation and interior switches.

Power Liftgate:

Available on some higher trims.

🔧 Maintenance

Oil Change:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (refer to manual for specifics).

Engine Air Filter:

Every 15,000-30,000 miles (24,000-48,000 km)

Spark Plugs:

Varies by plug type (e.g., Platinum: 100,000 miles; Copper: 30,000 miles). Consult manual for specific engine and plug type.

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km), especially under severe driving conditions.

Engine Oil:

SAE 5W-30 or 5W-20 (check owner's manual for exact specification and API rating)

Coolant:

Chrysler/Dodge HOAT (Hybrid Organic Additive Technology) coolant, typically orange or pink (refer to manual for Mopar part number or equivalent specification)

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF+4 or Mopar Power Steering Fluid (check manual)

Common Problems:

Transmission solenoid/pump failures (especially 41TE/42LE), EGR valve issues, Power window motor failures, Suspension wear (ball joints, tie rod ends), Overheating (coolant leaks, thermostat issues), Power sliding door mechanism faults, Alternator failure.

📚 Vehicle History

Dodge Legacy:

Dodge has a long history of producing reliable and practical vehicles, particularly in the minivan segment with the Caravan and its iterations.

Fourth Gen Launch:

The RS generation debuted for the 2001 model year, representing a significant redesign with updated styling, interior, and powertrains.

Mid Cycle Refresh:

Received updates and powertrain changes throughout its run, including the introduction of the 4.0L V6 engine in later years.

Manufacturing Location:

Primarily Windsor, Ontario, Canada; Saltillo, Mexico

Production Period Covered:

2001-2007 (this specific manual covers this range)

🏆 Awards & Recognition

Safety Awards:

Received some safety accolades from organizations like IIHS and NHTSA during its production run, though ratings varied by year and specific configuration.

Consumer Reports:

Historically received mixed reviews from Consumer Reports regarding reliability, particularly in later years. Manual provides insights for addressing common issues.