🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Generation:

RS

Production Years Covered:

2001-2007

Platform:

Chrysler NS/GS Minivan Platform

👋 Introduction

Segment:

Mid-size Minivan

Target Audience:

DIY mechanics, professional repair shops, fleet maintenance personnel.

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza.

Vehicle Strengths:

Spacious interior, versatile seating configurations, available AWD (on some models), comfortable ride.

Manual Value Proposition:

Provides essential, in-depth technical information required for diagnosing, repairing, and maintaining the Dodge Caravan across multiple model years, enabling significant cost savings for owners and technicians.

📋 Manual Details

Primary Coverage:

Mechanical and electrical systems, bodywork, maintenance, diagnostics, repair procedures.

Specific Systems Covered:

Engine, Transmission, Drivetrain, Brakes, Steering, Suspension, HVAC, Fuel System, Electrical System, Ignition System, Exhaust System, Cooling System, Body Control Modules (BCM), Powertrain Control Module (PCM), Audio System, Safety Systems (Airbags, ABS), Body Interior and Exterior.

Estimated Page Count:

1500-2500+ pages (typical for comprehensive workshop manuals of this era)

Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Detailed diagnostics, component testing, timing procedures, fuel injection, emissions control, cooling system overhaul, lubrication, engine mechanical specifications, and repair procedures for all gasoline engines offered.

Transmission Systems:

Service and repair procedures for automatic transmissions, including torque converter, valve body, clutch packs, seals, solenoids, hydraulic circuits, fluid specifications, and diagnostic trouble codes (DTCs).

Drivetrain Systems:

Front-wheel drive (FWD) axle and CV joint inspection, replacement, differential service, and related components.

Brake Systems:

Disc brake component replacement (pads, rotors, calipers), drum brake service (rear), parking brake adjustment, ABS system diagnostics and repair, hydraulic system bleeding, and specifications.

Steering And Suspension:

Power steering system (pump, rack, hoses), wheel alignment specifications, strut and shock absorber replacement, ball joint and tie rod end service, suspension component inspection.

Electrical And Ignition:

Complete wiring diagrams, fuse box layouts, starter motor, alternator, battery service, ignition system (spark plugs, coils, wiring), lighting systems, power windows, door locks, and instrument cluster diagnostics.

Body And Interior:

Door panel removal, seat adjustment/replacement, interior trim, exterior panel replacement (fenders, bumpers, doors), glass replacement, and body hardware adjustments.

Maintenance Procedures:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, tire rotation, air filter replacement, cabin air filter replacement, and general inspections.

Troubleshooting Guides:

Step-by-step diagnostic flowcharts for common drivability issues, electrical faults, and mechanical failures, often tied to Diagnostic Trouble Codes (DTCs).

Repair Procedures:

Detailed, illustrated instructions for component removal, installation, and adjustment for virtually all vehicle systems. Includes torque specifications for critical fasteners.

Diagnostic Procedures:

Procedures for using scan tools, multimeter testing, and specialized equipment to diagnose issues within engine control, transmission control, ABS, and other electronic modules.

Depth Level:

Comprehensive: Covers basic maintenance to advanced engine and transmission overhauls, electrical system troubleshooting, and body repair.

Diagnostic Tools:

References diagnostic trouble codes (DTCs) and diagnostic procedures that would typically require an OBD-II scanner.

Schematics:

Includes detailed electrical wiring diagrams for all major systems.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable for keywords and part numbers.

Printability:

Designed for printing specific sections or the entire manual.

Quality:

Dependent on the original source; typically clear text and diagrams.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Content Scope:

Comprehensive workshop manual covering all aspects of repair and maintenance.

⚙️ Engine Specifications

Engine Option 1:

2.4L 16V DOHC I4 (GEMA engine family)

Engine Option 1 Power:

Approx. 150 hp @ 5800 rpm

Engine Option 1 Torque:

Approx. 160 lb-ft @ 4000 rpm

Engine Option 2:

3.3L 12V OHV V6 (EGA engine family)

Engine Option 2 Power:

Approx. 180 hp @ 5000 rpm

Engine Option 2 Torque:

Approx. 205 lb-ft @ 3500 rpm

Engine Option 3:

3.8L 12V OHV V6 (EGH engine family)

Engine Option 3 Power:

Approx. 205 hp @ 5200 rpm

Engine Option 3 Torque:

Approx. 235 lb-ft @ 4000 rpm

Engine Control System:

Sequential Multi-Port Fuel Injection (MPI) with Electronic Control Module (ECM).

Emissions Control:

Catalytic converter, EGR system, Oxygen sensors, evaporative emission control system.

Fuel Type:

Unleaded Gasoline

Fuel Octane Rating:

87 octane recommended for all engines (consult manual for specific variations).

Fuel Delivery:

In-tank electric fuel pump, fuel filter, fuel rail.

🔧 Transmission

Transmission Type:

4-speed Automatic Transmission (41TE / 42LE)

Optional Transmission:

All-wheel drive (AWD) available with V6 engines on certain models.

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approx. 4.5-5.5 quarts (4.3-5.2 liters) for refill (consult manual for exact capacity).

Transmission Control:

Electronic control with torque converter lock-up.

📐 Dimensions

Wheelbase:

Approx. 112.1 inches (2847 mm)

Length:

Approx. 189.4 inches (4811 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 67.7 inches (1720 mm)

Wheel Bolt Pattern:

5 x 4.5 inches (5 x 114.3 mm)

Wheel Size Standard:

15-inch wheels

Tire Size Standard:

P215/65R15 (consult manual for specific fitments)

Cargo Volume Max:

Approx. 140.5 cubic feet (with second and third rows folded/removed)

Curb Weight:

Approx. 3700 - 4200 lbs (1678 - 1905 kg) depending on configuration

Towing Capacity:

Up to 3,800 lbs (1,724 kg) with optional towing package and V6 engine (consult manual for exact specifications).

🛡️ Safety Features

NHTSA Front Impact Rating:

4-star (driver), 4-star (passenger) for 2001-2007 models (typical, verify specific year).

IIHS Crash Test Performance:

Varies by year and specific test; generally fair to good ratings for the era.

ABS:

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

Traction Control:

Optional or standard on some models, especially those with AWD.

Airbags:

Standard front driver and passenger airbags. Optional side curtain airbags available on some later models.

Seat Belts:

3-point seat belts for all seating positions, with pretensioners for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Audio System Options:

AM/FM radio with CD player, cassette player (early models), optional premium sound systems, rear-seat entertainment systems (optional on higher trims).

Cruise Control:

Standard on most models.

Rear Parking Assist:

Optional on some models.

Connectivity Features:

Limited by era; primarily focused on audio input (CD, cassette). No integrated Bluetooth or USB connectivity in standard factory systems.

🔧 Maintenance

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first, with synthetic blend or full synthetic oil. (Consult manual for specific engine and oil type recommendations).

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Platinum-tipped plugs: 100,000 miles (160,000 km). Consult manual for exact type and interval.

Transmission Fluid Change:

Every 60,000 miles (96,000 km) or as per severe service schedule (check manual).

Coolant Flush:

Every 100,000 miles (160,000 km) or 5 years for HOAT coolant (check manual).

Engine Oil Specification:

SAE 5W-30 synthetic blend or full synthetic (API certified). Consult manual for specific engine requirements.

Coolant Specification:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT (Orange) or equivalent, mixed 50/50 with distilled water.

Brake Fluid Specification:

DOT 3

Common Wear Items:

CV axles, wheel bearings, front struts/shocks, sway bar links, front brake pads/rotors, exhaust components (muffler, catalytic converter).

Powertrain Concerns:

Transmission solenoid issues, radiator leaks, oil cooler line leaks (especially on 3.3L and 3.8L V6), intake manifold gasket leaks (on certain V6s).

Electrical Concerns:

Power sliding door module failures, intermittent power window issues, BCM (Body Control Module) glitches, instrument cluster failures.

📚 Vehicle History

Dodge Brand:

Dodge, a division of Chrysler, has a long history of producing robust and versatile vehicles, particularly known for its trucks and minivans.

Generation Rs:

The RS generation (2001-2007) represented a significant redesign over the previous generation (NS), featuring more modern styling, improved interior packaging, and updated powertrains. It marked the final generation of the Caravan nameplate under Chrysler's ownership before the introduction of the Dodge Grand Caravan in later iterations.

Manufacturing Locations:

Primarily Windsor, Ontario, Canada (Windsor Assembly Plant).

Key Updates During Production:

Minor styling refreshes, powertrain updates, and feature enhancements throughout the model run (e.g., introduction of Stow 'n Go seating concept later in the generation, though this manual covers the pre-Stow 'n Go era primarily).

🏆 Awards & Recognition

Family Vehicle Awards:

The Caravan/Grand Caravan platform has historically received accolades in the family vehicle segment, often recognized for its practicality and value. Specific awards for the 2001-2007 model years would need verification through automotive review archives.

Consumer Reports Reliability:

Reliability ratings varied by year and powertrain, with some years showing average to below-average reliability compared to competitors. The manual is crucial for addressing potential common issues.