Dodge Caravan 2001-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Product Name: Dodge Caravan 2001-2007 Service Repair Manual Generation Generation Code: RS Codes Platform Code: NS (facelifted) 👋 Introduction Market Position Segment:...

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

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Product Name:

Dodge Caravan 2001-2007 Service Repair Manual

Generation

Generation Code:

Codes

Platform Code:

NS (facelifted)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, tradespeople, anyone needing versatile cargo and passenger capacity.

Competitive Analysis

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Freestar/Windstar, Chevrolet Venture/Uplander.

Key Features

Versatility:

Flexible seating arrangements (Stow 'n Go on later models), ample cargo space.

Engine Options:

Reliable V6 engine options providing good balance of power and efficiency.

Practicality:

Designed for everyday family use, commuting, and hauling.

📋 Manual Details

Coverage Areas

Model Years Covered:

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

Trim Levels Covered:

All trim levels including SE, SXT, ES, and specific regional variants.

Page Count

Estimated Page Count:

Thousands (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, diagnostics, rebuild procedures for all gasoline engines.

Engine Performance:

Fuel injection system, ignition system, emission control systems, turbocharging (if applicable).

Transmission Automatic:

Detailed repair and overhaul procedures for automatic transmissions (e.g., 41TE, 42LE).

Transmission Manual:

Repair and overhaul for manual transmission variants (less common in this generation).

Drivetrain:

Front-wheel drive axle shafts, differentials, universal joints.

Suspension:

Front and rear suspension systems, components, alignment specifications, and troubleshooting.

Steering:

Power steering system, steering gear, tie rods, steering column.

Brakes:

Hydraulic brake system, anti-lock braking system (ABS), parking brake, disc and drum brake component replacement.

Electrical System:

Full wiring diagrams, component locations, fuse box layouts, charging system, starting system.

Body Interior:

Body panel removal and installation, interior trim, seating systems, power sliding doors, liftgate.

Body Exterior:

Body panel repair, bumper systems, glass replacement, exterior trim.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, repair, and component replacement.

Climate Control:

Automatic climate control systems (if equipped).

Safety Restraint System:

Airbag system diagnosis and service, seatbelt mechanisms.

Infotainment Audio:

Radio, speaker systems, entertainment options.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component replacement and repair.

Diagnostic Procedures:

OBD-II diagnostics, specific sensor testing, system checks.

Rebuilding Procedures:

Engine and transmission rebuild procedures with specifications.

Specifications Data:

Torque values, clearances, fluid capacities, electrical specifications.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls.

Diagnostic Capabilities:

Advanced diagnostic procedures and information for all major systems.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text within PDF for quick information retrieval.

Print Quality

Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

3.3L V6 (EGA)

Displacement 1:

3301 cc (201.5 ci)

Horsepower 1:

180 hp @ 5000 rpm (approx.)

Torque 1:

205 lb-ft @ 3600 rpm (approx.)

Secondary Engine

Engine Code 2:

3.8L V6 (L32, L67)

Displacement 2:

3778 cc (230.5 ci)

Horsepower 2:

190-215 hp @ 5000 rpm (approx., varies by supercharged/non-supercharged)

Torque 2:

230-270 lb-ft @ 3200 rpm (approx., varies by supercharged/non-supercharged)

Fuel System

Induction Type:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Type:

4-speed Automatic Transaxle (e.g., 41TE/42LE)

Optional

Type:

N/A (Automatic was standard for this generation)

Features

Driver Selectable Modes:

Some models may feature a 'Winter' or 'Performance' mode.

Fluid Specifications

Fluid Type:

ATF+4 (Chrysler Mopar)

Fluid Capacity

Capacity:

Approx. 4.0 - 5.0 quarts (9.5 L) for a fluid change.

📐 Dimensions

Exterior

Length:

Approx. 193.7 inches (4920 mm)

Width:

Approx. 76.0 inches (1930 mm)

Height:

Approx. 67.7 inches (1720 mm)

Wheelbase:

Approx. 113.0 inches (2870 mm)

Interior

Seating Capacity:

7 or 8 passengers (depending on configuration)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 27.3 cu ft (861 L)

Cargo Volume With 3Rd Row Folded:

Approx. 83.7 cu ft (2370 L)

Cargo Volume With 2Nd And 3Rd Rows Folded:

Approx. 141.1 cu ft (4000 L)

Weights

Curb Weight:

Approx. 3800 - 4200 lbs (1724 - 1905 kg)

Gross Vehicle Weight Rating:

Approx. 5700 - 6000 lbs (2585 - 2722 kg)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Driver:

4 Stars (2001-2007 models, generally)

NHTSA Front Crash Test Passenger:

4 Stars (2001-2007 models, generally)

IIHS Front Offset Score:

Acceptable to Good (varies by year, with improvements over time)

Active Features

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

Traction Control:

Optional Traction Control System (TCS) on some models.

Passive Features

Airbags:

Front airbags for driver and passenger. Optional side airbags available on some trims.

Seat Belts:

Three-point seat belts for all seating positions.

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD players, some with cassette. Premium Infinity sound systems available on higher trims.

Rear Entertainment:

Optional rear-seat video entertainment system (RES) with DVD player in later years.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional rear parking assist sensors on some models.

Connectivity

Oem Bluetooth:

Not typically available from the factory for this generation.

Oem Navigation:

Rarely available, if at all, for this generation of Caravan.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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).

Air Filter Replacement:

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

Spark Plug Replacement:

30,000-100,000 miles (48,000-160,000 km) depending on spark plug type (conventional vs. platinum/iridium).

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-96,000 km), or as specified by the manual, especially for heavy use.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 API Certified (check manual for exact specification and viscosity grade depending on temperature).

Coolant Type:

Chrysler Type MS-9769 (Orange Long-Life).

Brake Fluid Type:

DOT 3.

Known Issues

Transmission Hard Shifting:

Common on some automatic transmissions; often related to solenoid pack, valve body, or fluid condition.

Rear Heat Exchanger Leaks:

Can cause coolant leaks into the cabin or a sweet smell. Requires replacement of the heater core.

Power Sliding Door Motors:

Motors can fail or experience electrical issues, affecting door operation.

Ignition Coil Failure:

Can lead to misfires and rough running, often a concern on V6 engines.

Suspension Components:

Wear on ball joints, tie rod ends, and control arm bushings due to vehicle weight and usage.

📚 Vehicle History

Brand Heritage

Brand:

Dodge, a division of Chrysler (now Stellantis), has a long history in American automotive manufacturing.

Model Evolution

Generation Introduction:

The Dodge Caravan (and its Plymouth Voyager/Chrysler Town & Country siblings) revolutionized the minivan segment in the mid-1980s.

Generation 2001 2007:

This period represents the third generation (RS) of the Dodge Caravan, which received significant updates and facelifts.

Production

Manufacturing Locations:

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

Model End Of Life:

The Caravan continued production beyond 2007, but this manual specifically covers the 2001-2007 model years.

🏆 Awards & Recognition

Recognitions

Ward Best Engines:

The 3.8L V6 engine variant has received recognition in the past for its smooth power delivery.

Consumer Reports Ratings:

Ratings varied throughout the production years, with some years showing better reliability scores than others. The manual provides insights into common issues.

Certifications

Safety Certifications:

Compliant with all federal motor vehicle safety standards (FMVSS) for its production years.