Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007
Product Name:
2001-2007 Dodge Caravan Service & Repair Manual
Target Audience:
Owners seeking to perform their own maintenance and repairs, independent repair shops, and automotive enthusiasts.
Competitors:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Vans, Kia Sedona.
Value Proposition:
Provides factory-accurate information for servicing and repairing the 2001-2007 Dodge Caravan, enabling cost savings and proper vehicle maintenance.
Ease Of Use:
Structured for ease of navigation with clear headings, diagrams, and troubleshooting flows.
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine performance diagnostics, transmission (automatic and manual), drivetrain components (axles, CV joints, differentials).
Chassis:
Brake system (ABS, disc, drum), suspension system (front and rear), steering system, wheels and tires.
Body And Electrical:
Body construction, exterior trim, interior trim, HVAC system, power accessories (windows, locks, seats), lighting system, instrument cluster, warning indicators, infotainment system, body control module (BCM), wiring diagrams for all circuits.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, tune-up procedures, tire rotation, brake inspection, battery maintenance.
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, electrical system diagnostics, mechanical system diagnostics, emissions system diagnostics.
Repair:
Step-by-step repair procedures for all major components and systems, including engine removal/installation, transmission overhaul, brake caliper replacement, suspension component replacement, HVAC system repair, electrical component replacement.
Special Procedures:
Torque specifications for all fasteners, diagnostic tool usage, special tool requirements, wheel alignment procedures, refrigerant handling and service, diagnostic system checks.
Depth:
Comprehensive factory-level detail, including disassembly, assembly, adjustments, testing, and troubleshooting for all vehicle systems. Suitable for professional technicians and advanced DIY mechanics.
Engine Type 1:
3.3L OHV V6 (EGA)
Displacement 1:
3.3 Liters (203 cubic inches)
Bore X Stroke 1:
3.92 in x 3.57 in (99.5 mm x 90.7 mm)
Compression Ratio 1:
9.3:1
Horsepower 1:
Approx. 180 hp @ 4,600 rpm
Torque 1:
Approx. 205 lb-ft @ 3,200 rpm
Fuel System 1:
Multi-port Electronic Fuel Injection (MPI)
Engine Management System 1:
Chrysler JTEC or NGC (Next Generation Controller)
Engine Type 2:
3.8L OHV V6 (L32)
Displacement 2:
3.8 Liters (230 cubic inches)
Bore X Stroke 2:
3.92 in x 3.28 in (99.5 mm x 83.3 mm)
Compression Ratio 2:
9.0:1
Horsepower 2:
Approx. 200-215 hp @ 4,800-5,000 rpm
Torque 2:
Approx. 230-245 lb-ft @ 3,800-4,000 rpm
Fuel System 2:
Multi-port Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Transmission Type 1:
4-speed Automatic Transaxle (41TE/42LE)
Transmission Type 2:
5-speed Manual Transaxle (NV3500 - less common)
Transmission Control:
Electronic control with torque converter clutch (TCC).
Automatic Transmission Fluid:
ATF+4 (Chrysler Mopar)
Automatic Transmission Fluid Capacity:
Approx. 4.0-5.5 quarts (3.8-5.2 liters) for refill after pan removal.
Wheelbase:
Approx. 119.2 inches (3028 mm)
Length:
Approx. 189.4 inches (4811 mm) for standard wheelbase, 201.5 inches (5118 mm) for long wheelbase.
Width:
Approx. 71.9 inches (1826 mm)
Height:
Approx. 68.9 inches (1750 mm)
Cargo Volume Behind 1St Row:
Approx. 140.5 cu ft (3978 L) for long wheelbase.
Cargo Volume Behind 2Nd Row:
Approx. 76.7 cu ft (2172 L) for long wheelbase.
Curb Weight:
Approx. 3,800 - 4,300 lbs (1724 - 1950 kg), depending on configuration.
Gross Vehicle Weight Rating Gvwr:
Approx. 5,700 - 6,000 lbs (2585 - 2722 kg).
NHTSA Rollover Rating:
Typically 4 out of 5 stars for minivan segment.
Braking System:
Front disc brakes, rear drum brakes (standard), optional rear disc brakes, Anti-lock Braking System (ABS) available.
Traction Control:
Available on some models/trims.
Airbags:
Standard front airbags for driver and passenger. Optional side-impact airbags available on some models.
Seat Belts:
3-point seat belts for all occupants, LATCH child seat anchors.
Child Safety:
Child safety rear door locks, available rear-seat entertainment systems.
Audio System:
Factory AM/FM/CD players, optional Infinity speaker systems, available CD/DVD changer.
Navigation:
Optional factory navigation system on higher trim levels.
Parking Assist:
Optional rear park assist sensors.
Satellite Radio:
Available Sirius Satellite Radio.
Seating Options:
Available Stow 'n Go seating, heated front seats, power adjustable driver and passenger seats.
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first, under normal driving conditions. Refer to manual for severe driving conditions.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Approximately 100,000 miles (160,000 km) for platinum or iridium plugs.
Coolant Flush Replacement:
Every 100,000 miles (160,000 km) or 5 years, using Mopar OAT coolant.
Engine Oil Specification:
SAE 5W-30 viscosity grade, API certified (e.g., MS-6395).
Coolant Specification:
Mopar OAT (Organic Additive Technology) 50/50 mix, typically orange in color.
Brake Fluid Specification:
DOT 3 or DOT 4 (check specific label on reservoir).
Power Steering Fluid:
Chrysler Power Steering Fluid or equivalent Mopar product.
Transmission Issues:
Intermittent shifting problems, torque converter shudder, potential for solenoid failure in the 41TE/42LE transmission.
Suspension Components:
Premature wear of ball joints, tie rod ends, and sway bar links, especially in areas with poor road conditions.
Electrical Systems:
Issues with power window regulators, HVAC blower motor resistor, and instrument cluster problems can occur.
Engine Performance:
Intake manifold gasket leaks (3.3L), occasional ignition coil pack failures.
Body Corrosion:
Rust development on rocker panels, rear wheel wells, and liftgate can be an issue in certain climates.
Parent Company:
Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles).
Generation:
Third Generation (1996-2000), Fourth Generation (2001-2007).
Design Changes:
The 2001 model year marked a significant redesign for the Caravan, introducing a more aerodynamic profile, improved interior packaging, and updated powertrains. Longer wheelbase option (Grand Caravan) became standard across the lineup in some markets.
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
Key Updates During Generation:
Introduction of the 'Stow 'n Go' seating system in 2005 for enhanced cargo versatility, powertrain updates including more powerful versions of the V6 engines, introduction of Sirius Satellite Radio option.
