🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Model Years Covered:

2001, 2002, 2003, 2004, 2005

Generation Name:

Fourth Generation (RS)

Chassis Code:

RS

👋 Introduction

Market Segment:

Minivan / Family Vehicle

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager.

Vehicle Appeal:

Known for its versatility, spacious interior, Stow 'n Go seating (introduced later in generation, but concept of flexible seating was key), and practicality for families. Often offered with Stowaway (in-floor) storage.

Manual Value Proposition:

Provides professional-level repair and maintenance information identical to what dealer technicians utilize, enabling accurate diagnosis and repair, reducing reliance on costly shop labor.

📋 Manual Details

Coverage Scope:

Comprehensive Workshop Service and Repair

Estimated Page Count:

Over 2000 pages (typical for factory service manuals of this era)

Manual Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (PCM/ECM), automatic transmission, manual transmission (if applicable).

Chassis:

Suspension (front and rear), steering system, braking system (including ABS), wheels, tires, driveline (FWD, AWD components).

Electrical:

Lighting system, instrument panel and gauges, power windows, power locks, mirrors, seats, wipers and washers, horn, audio systems, starter and charging system, body control module (BCM), fuse and relay information, wiring diagrams.

Body:

Body panels, doors, windows, glass, interior trim, exterior trim, seats, HVAC system, safety restraints (airbags, seat belts).

Maintenance:

Scheduled maintenance intervals, fluid checks and changes, filter replacements, lubrication, tire rotation.

Repair:

Engine component overhaul, transmission repair, brake caliper replacement, suspension strut replacement, electrical component diagnosis and replacement, body panel repair, HVAC system servicing.

Diagnostics:

Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) and their meanings, procedures for using diagnostic scan tools.

Specifications:

Torque specifications for fasteners, electrical specifications (voltages, resistance), performance data, component dimensions.

Depth Of Coverage:

Full factory-level detail, including diagnostic procedures, component removal and installation, overhaul instructions, and wiring diagrams. Suitable for professional technicians and advanced DIY mechanics.

📊 Manual Specifications

File Format Details:

Searchable PDF for easy navigation and keyword access. High-resolution scans for clear diagrams and text.

Print Quality:

High resolution for clear viewing of diagrams, schematics, and text. Optimized for digital viewing and printing individual pages.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

2.4L 4-cylinder (e.g., EDZ), 3.3L V6 (e.g., EDB), 3.8L V6 (e.g., EGT).

3.3L V6 Power Output:

Approx. 180-185 hp @ 4800-5000 rpm, 200-205 lb-ft torque @ 3600-3800 rpm (specifics vary by year).

3.8L V6 Power Output:

Approx. 200-215 hp @ 5000-5200 rpm, 230-240 lb-ft torque @ 3200-4000 rpm (specifics vary by year).

Fuel Delivery:

Multi-port fuel injection (MPI).

Spark Plug Type:

Platinum or Iridium (e.g., Champion, NGK - consult specific year for exact part number and gap).

Engine Oil Type:

SAE 5W-30 (most common, verify with manual).

Engine Oil Capacity:

Approx. 4.5-5.0 quarts (4.3-4.7 liters) for V6 engines (verify with manual).

🔧 Transmission

Transmission Options:

4-speed automatic transmission (e.g., 41TE, 42LE).

Optional Transmissions:

All-wheel-drive (AWD) models may have different transmission configurations (e.g., 45RFE).

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 7176 / MS-9602 or equivalent - crucial to use correct fluid).

Transmission Fluid Capacity:

Approx. 4-5 quarts (3.8-4.7 liters) for a drain and fill (verify with manual).

📐 Dimensions

Wheelbase:

Approx. 119.3 inches (3030 mm).

Length:

Approx. 189.4 inches (4811 mm).

Width:

Approx. 72.0 inches (1829 mm).

Height:

Approx. 68.1 inches (1730 mm).

Cargo Volume Behind 3Rd Row:

Approx. 25.9 cubic feet (733 liters).

Cargo Volume Max:

Approx. 145.8 cubic feet (4129 liters) with rear seats removed.

Curb Weight:

Approx. 3700-4100 lbs (1678-1860 kg) depending on engine and configuration.

Gross Vehicle Weight Rating Gvwr:

Approx. 5500-6000 lbs (2495-2722 kg) depending on configuration.

Wheelbase Bolt Pattern:

5 x 4.5 inches (5 x 114.3 mm).

Standard Tire Size:

P215/70R15 (common, verify with specific trim/year).

Optional Tire Size:

P215/65R16, P225/60R17 (for higher trims or optional wheels).

🛡️ Safety Features

NHTSA Frontal Crash Test Driver:

4 stars (2001-2005 models, based on available data, ratings can vary slightly by year and test protocol).

NHTSA Frontal Crash Test Passenger:

4 stars (2001-2005 models).

NHTSA Side Impact Front Seat Passenger:

5 stars (2001-2005 models, for models equipped with side airbags).

ABS:

Standard or optional depending on trim level.

Traction Control:

Optional on some models, often paired with AWD.

Airbags:

Front airbags standard. Optional side airbags for front occupants in later years/higher trims.

Seat Belts:

Three-point seat belts for all occupants, front seat pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM/CD or Cassette players. Optional Infinity premium audio systems were available. Steering wheel audio controls on higher trims.

Rear Seat Entertainment:

Optional rear-seat entertainment systems (e.g., DVD players, video screens) were available on some higher trim levels.

Cruise Control:

Standard or optional depending on trim.

Parking Sensors:

Optional rear parking assist sensors on some models.

Auxiliary Input:

Not standard. Aftermarket solutions were common for auxiliary audio inputs.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe driving may require more frequent changes. (Consult manual for exact recommendation).

Transmission Fluid Change Interval:

Every 60,000-100,000 miles (96,000-160,000 km), or as specified in severe duty schedule. Crucial to check condition and level regularly. (Consult manual for exact recommendation).

Engine Air Filter Replacement:

Every 30,000-50,000 miles (48,000-80,000 km), or as needed based on inspection. (Consult manual for exact recommendation).

Spark Plug Replacement:

For platinum/iridium plugs, typically 100,000 miles (160,000 km). (Consult manual for exact recommendation and type).

Coolant Type:

Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) or MOPAR OAT (Organic Acid Technology) coolant, typically a 50/50 mix with distilled water. Color may vary (e.g., orange or yellow). (Consult manual for exact specification).

Brake Fluid Type:

DOT 3 or DOT 4 (verify with manual, generally DOT 3 is common for this era).

Power Steering Fluid Type:

Mopar Power Steering Fluid or equivalent (Dexron III ATF may be acceptable in some cases, verify with manual).

Transmission Problems:

Common issues include solenoid pack failures, torque converter shudder, and worn clutch packs, especially in earlier models or with high mileage/poor maintenance. ATF+4 fluid is critical.

Engine Problems:

Potential for rear main seal leaks, intake manifold gasket leaks (on some V6 engines), and ignition coil issues. Timing belt is not applicable, uses a timing chain.

Suspension Wear:

Front suspension components like ball joints, tie rod ends, and wheel bearings can wear over time, leading to noise and steering issues.

Power Sliding Doors:

Electric motors for power sliding doors can fail, or the guide rails can become obstructed or worn, leading to malfunction.

HVAC Blower Motor:

Blower motor resistor or the blower motor itself can fail, leading to loss of fan speed control or no fan operation.

📚 Vehicle History

Dodge Legacy In Minivans:

Dodge pioneered the modern minivan segment with the original Dodge Caravan in 1984. This legacy established Dodge as a leader in the family vehicle market for decades.

Fourth Generation Introduction:

The fourth generation (RS) debuted for the 2001 model year, representing a significant redesign from the previous generation. It offered improved aerodynamics, updated styling, and enhanced safety features.

Key Innovations Of Generation:

Introduction of Stow 'n Go seating system was a major highlight, although it became more prominent in subsequent years. Redesigned interior and improved ride quality.

Production Locations:

Primarily manufactured at Chrysler's Windsor Assembly Plant in Windsor, Ontario, Canada.

Production Years Of Generation:

2001-2007 (though this manual covers up to 2005).

🏆 Awards & Recognition

Consumer Satisfaction:

While specific awards for this generation are less prominent, the Caravan line consistently ranked as a popular choice for families due to its practicality and value proposition, often appearing on 'most popular' lists.

Kbb Used Car Value:

Historically, the Caravan has been recognized for its strong resale value in the minivan segment, particularly in its prime years.