🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Generation Designation:

Fourth Generation (RS)

Generation Years:

2001-2007

Platform Code:

RS

👋 Introduction

Segment:

Minivan

Target Audience:

Vehicle owners seeking to perform DIY maintenance and repairs, independent repair shops, automotive technicians.

Key Competitors:

Toyota Sienna, Honda Odyssey, Chevrolet Venture/Montana, Ford Freestar/Windstar, Kia Sedona, Mercury Monterey.

Manual Value:

Provides detailed, factory-level information to reduce repair costs and ensure proper vehicle maintenance.

Vehicle Appeal:

Known for its spacious interior, flexible seating configurations (Stow 'n Go on later models), and family-friendly features.

📋 Manual Details

Applicable Years:

2003, 2004, 2005, 2006, 2007

Engine Variants Covered:

All, including 2.4L DOHC I4, 3.3L OHV V6, 3.8L OHV V6

Trim Levels Covered:

All (SE, SXT, ES, etc.)

Estimated Page Count:

2000-3000+ (typical for comprehensive workshop manuals of this era)

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical (2.4L DOHC, 3.3L OHV, 3.8L OHV), fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/PCM diagnostics).

Transmission:

Automatic Transaxle (41TE, 42LE, 45RFE) service, diagnostics, and overhaul procedures.

Drivetrain:

Front-wheel drive axle shafts, differential, transfer case (if applicable), driveshafts.

Suspension:

Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), alignment specifications.

Steering:

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

Brakes:

Front and rear brake systems (disc/drum), ABS system, parking brake, hydraulic components.

Electrical:

Battery, starting system, charging system, lighting systems, interior and exterior electrical components, wiring diagrams for all systems, Body Control Module (BCM).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, and service.

Body:

Body panels, doors, windows, glass, interior trim, exterior trim, body repair procedures, structural components.

Restraint Systems:

Airbag system (SRS) components and diagnostics, seat belts.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-up procedures.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, common fault diagnosis.

Repair:

Step-by-step repair procedures for all major components and systems.

Overhaul:

Complete overhaul procedures for engines and transmissions.

Specifications:

Torque specifications, clearances, fluid capacities, electrical values.

Diagnostics:

OBD-II diagnostic trouble codes (DTCs), diagnostic tool usage, electrical system testing.

Depth:

Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

Compatibility:

Viewable on most devices with PDF reader (Adobe Acrobat Reader recommended).

Searchability:

Typically features searchable text for quick information retrieval.

Image Resolution:

High-resolution images, diagrams, and schematics for clarity.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine 1 Displacement:

2.4 Liters

Engine 1 Configuration:

Inline 4-cylinder (I4), DOHC (2.4L GEMA)

Engine 1 Horsepower:

Approx. 150 hp @ 5800 rpm

Engine 1 Torque:

Approx. 165 lb-ft @ 4000 rpm

Engine 2 Displacement:

3.3 Liters

Engine 2 Configuration:

V6, OHV (3.3L EER/EGA)

Engine 2 Horsepower:

Approx. 180 hp @ 5000 rpm

Engine 2 Torque:

Approx. 205 lb-ft @ 3400 rpm

Engine 3 Displacement:

3.8 Liters

Engine 3 Configuration:

V6, OHV (3.8L L32)

Engine 3 Horsepower:

Approx. 200-205 hp @ 5200 rpm

Engine 3 Torque:

Approx. 230-235 lb-ft @ 3400 rpm

Fuel Delivery:

Electronic Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane recommended

Emission Controls:

Catalytic converter, EGR system, evaporative emissions control.

🔧 Transmission

Transmission Type:

4-Speed Automatic Transaxle (41TE for 2.4L, 42LE for 3.3L V6, 45RFE for 3.8L V6)

Optional Transmission:

N/A (Automatic was standard across the lineup)

Transmission Fluid Spec 33 V6:

ATF+4 (Chrysler Material Standard MS-9602)

Transmission Fluid Spec 2 4 I4:

ATF+4 (Chrysler Material Standard MS-9602)

Transmission Fluid Capacity:

Approx. 3.7-4.0 quarts (dry fill); 2.8-3.0 quarts (fluid change)

📐 Dimensions

Wheelbase:

Approx. 119.3 inches

Length:

Approx. 189.2 inches

Width:

Approx. 74.1 inches

Height:

Approx. 68.4 inches

Passenger Volume:

Approx. 150-160 cubic feet

Cargo Volume Behind 1St Row:

Approx. 140+ cubic feet

Cargo Volume Behind 2Nd Row:

Approx. 70-80 cubic feet

Curb Weight:

Approx. 3,800 - 4,300 lbs (depending on engine and configuration)

Towing Capacity:

Up to 3,800 lbs (with appropriate engine and factory tow package)

🛡️ Safety Features

NHTSA Rollover Rating:

4 out of 5 stars (typical for this generation)

IIHS Crash Test Performance:

Generally good for its class, but older designs may not meet current stringent standards.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional (often tied to higher trims or specific packages)

Airbags:

Driver and front passenger airbags, optional side airbags.

Seat Belts:

Three-point seat belts for all occupants, driver and front passenger seat belt pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional CD/DVD changer, optional rear-seat entertainment system (in later years).

Navigation:

Optional factory navigation system available on higher trims.

Cruise Control:

Standard cruise control.

Power Windows:

Standard power windows and door locks.

Remote Keyless Entry:

Available/Standard depending on trim level.

🔧 Maintenance

Oil Change Interval:

Every 5,000-7,500 miles or 6 months, whichever comes first (synthetic oil recommended for longer intervals).

Transmission Fluid Change Interval:

Every 30,000-60,000 miles, or as per severe duty schedule. Check manual for specific recommendations.

Coolant Flush Interval:

Every 30,000-60,000 miles or 3-5 years (depending on coolant type, HOAT recommended).

Spark Plug Replacement 2 4L:

Approx. 100,000 miles (if using platinum or iridium plugs)

Spark Plug Replacement V6:

Approx. 60,000-100,000 miles (depending on plug type, inspect at 60k)

Engine Oil Specification:

SAE 5W-30 (preferred), SAE 10W-30 may be acceptable based on temperature. API Certified, ILSAC GF-4 or later.

Coolant Specification:

Chrysler Type I (HOAT - Hybrid Organic Acid Technology) or equivalent. Mopar HOAT Antifreeze/Coolant (blue).

Brake Fluid Specification:

DOT 3

Power Steering Fluid Specification:

ATF+4 or Chrysler Power Steering Fluid (MS-5901)

Common Issue Power Sliding Doors:

Actuator failures, wiring harness issues, motor wear on power sliding doors.

Common Issue Transmission Hard Shifts:

Transmission control module (TCM) issues, fluid leaks, internal wear, especially on 41TE and 42LE units.

Common Issue Engine Oil Leaks:

Valve cover gasket, oil pan gasket, rear main seal leaks.

Common Issue Ac System:

Compressor clutch failure, refrigerant leaks, blend door actuator failures.

Common Issue Suspension Wear:

Ball joints, tie rod ends, control arm bushings can wear out prematurely.

Common Issue Evaporative Emission System:

Canister purge valve or vent valve failures leading to EVAP codes.

📚 Vehicle History

Dodge Legacy:

Dodge has a long history of producing practical and powerful vehicles, establishing itself in various segments including trucks, muscle cars, and minivans.

Caravan Introduction:

The Dodge Caravan (and its Plymouth Voyager sibling) pioneered the minivan segment in the early 1980s, revolutionizing family transportation.

Rs Generation Updates:

The 2001-2007 RS generation saw significant redesigns from earlier models, including improved aerodynamics, enhanced safety features, and more powerful engine options. Key updates include the introduction of the 2.4L GEMA engine and the Stow 'n Go seating system in later model years (post-2004).

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)

Production Span For This Generation:

2001-2007

🏆 Awards & Recognition

Initial Reception:

The Caravan was a segment leader and received numerous accolades for its practicality and innovation upon its introduction and throughout its generations.

Consumer Reports Ratings:

Ratings varied by year and specific model; often criticized for transmission reliability in earlier years of this generation but praised for utility.

Manual Certification:

This manual is designed to meet or exceed factory service information standards.