2006 Dodge Caravan Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2006 Codes Platform: NS (Fourth Generation) Body Style: Minivan 👋 Introduction Market Position Vehicle Segment: Mid-size Minivan Target Audience: Families, fleet...

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类型: Caravan

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标签: 2006 Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform:

NS (Fourth Generation)

Body Style:

Minivan

👋 Introduction

Market Position

Vehicle Segment:

Mid-size Minivan

Target Audience:

Families, fleet operators, commercial use.

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Chevrolet Uplander, Ford Freestar, Kia Sedona, Hyundai Entourage.

Key Features

Vehicle Selling Points:

Spacious interior, versatile seating arrangements, available all-wheel drive (AWD on some trims), comfortable ride, good value proposition.

Manual Purpose

Manual Value Proposition:

Provides in-depth, vehicle-specific repair and maintenance information, mirroring dealership technician resources, enabling accurate and efficient service.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z, Vehicle Specific

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete Overhaul, Diagnosis, Timing Belts/Chains, Seals, Gaskets, Pistons, Rings, Bearings, Valve Train, Cooling System, Lubrication System

Engine Performance:

Fuel Injection, Ignition System, Emission Controls (EGR, EVAP), Turbocharger/Supercharger (if applicable), Engine Control Module (ECM) Diagnosis

Transmission Manual:

Manual Transmission (if applicable): Overhaul, Clutch, Gearbox, Linkages

Transmission Automatic:

Automatic Transmission (41TE, 42LE): Overhaul, Valve Body, Torque Converter, Fluid Service, Electronic Controls, Diagnosis

Drivetrain:

Front Wheel Drive (FWD) Axles, CV Joints, Differential, Hubs, Wheel Bearings

Brakes:

Front and Rear Disc Brakes, ABS System, Hydraulic Lines, Master Cylinder, Power Booster, Parking Brake, Rotor/Pad Replacement, Caliper Service

Suspension:

Front MacPherson Struts, Rear Torsion Beam Axle, Coil Springs, Shock Absorbers, Control Arms, Ball Joints, Bushings, Sway Bars, Alignment Specifications

Steering:

Power Steering System, Steering Gear, Steering Column, Tie Rods, Power Steering Pump, Fluid Service, Diagnosis

Electrical System:

Battery, Charging System (Alternator), Starting System (Starter), Fuses, Relays, Wiring Diagrams, Lighting System, Ignition Switch

Body And Interior:

Body Panels, Doors, Hood, Tailgate, Bumpers, Seats, Interior Trim, Glass, Locks, Power Accessories (Windows, Doors, Mirrors), HVAC System Components, Seats, Upholstery

HVAC:

Air Conditioning (A/C) System, Heater Core, Blower Motor, Controls, Refrigerant Handling, Diagnosis

Comfort And Convenience:

Power Sliding Doors, Power Liftgate, Remote Keyless Entry, Cruise Control, Audio System, Navigation (if equipped)

Procedures Included

Diagnostic Procedures:

Troubleshooting Charts, DTC (Diagnostic Trouble Code) Interpretation, Component Testing, Scan Tool Usage

Maintenance Procedures:

Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Tire Rotation, Spark Plug Replacement, Brake Pad Replacement, Belt Replacement

Repair Procedures:

Step-by-Step Reassembly/Disassembly Guides for all major components, Component Replacement, Sealant Application, Torque Specifications

Overhaul Procedures:

Complete Engine Rebuild, Transmission Rebuild, Differential Service, Suspension Component Overhaul

Electrical Troubleshooting:

Detailed Wiring Diagrams, Pinpoint Tests, Circuit Diagnosis, Component Replacement Procedures

Technical Depth

Depth Of Coverage:

Comprehensive; Suitable for DIY enthusiasts, professional technicians, and dealerships.

Diagnostic Capabilities:

Advanced diagnostics with specific test procedures and expected results for various components and systems.

Rebuild Instructions:

Detailed step-by-step instructions for complete engine and transmission overhauls, including tolerances and specifications.

📊 Manual Specifications

File Format

File Format:

Printed Booklet

Print Quality

Print Quality:

High-resolution printing for clear diagrams and text.

Binding Type

Binding Type:

Professionally Bound (e.g., Spiral or Perfect Binding for lay-flat use)

Paper Type

Paper Type:

Durable, thick paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

3.3L (3301cc) V6 (2006)

Engine Code 1:

Displacement 1:

3.3 Liters

Cylinders 1:

Configuration 1:

SOHC V6

Horsepower 1:

180 hp @ 5000 rpm (approx.)

Torque 1:

205 lb-ft @ 3400 rpm (approx.)

Optional Engine

Engine Option 2:

3.8L (3778cc) V6 (Available on some trims)

Engine Code 2:

Displacement 2:

3.8 Liters

Cylinders 2:

Configuration 2:

SOHC V6

Horsepower 2:

200 hp @ 5000 rpm (approx.)

Torque 2:

230 lb-ft @ 3400 rpm (approx.)

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 20.0 gallons (75.7 Liters)

🔧 Transmission

Standard

Transmission Type Standard:

4-speed Automatic (41TE/42LE)

Optional

Transmission Type Optional:

None (4-speed Automatic was standard across most models)

Features

Transmission Control:

Electronically Controlled

Transmission Fluid Type:

ATF+4 (Mopar)

📐 Dimensions

Exterior

Wheelbase:

Approx. 119.0 inches (3023 mm)

Length:

Approx. 199.5 inches (5067 mm)

Width:

Approx. 76.7 inches (1948 mm)

Height:

Approx. 67.9 inches (1725 mm)

Cargo

Cargo Volume Behind 1St Row:

Approx. 140.5 cu ft (3979 Liters)

Cargo Volume Behind 2Nd Row:

Approx. 83.1 cu ft (2353 Liters)

Cargo Volume Behind 3Rd Row:

Approx. 30.3 cu ft (858 Liters)

Weights

Curb Weight:

Approx. 4,200 - 4,500 lbs (1905 - 2041 kg), varies by trim and options.

Gross Vehicle Weight Rating Gvwr:

Approx. 5,700 - 5,900 lbs (2585 - 2676 kg)

Towing Capacity:

Up to 3,800 lbs (1724 kg) with optional towing package.

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5 Stars

NHTSA Front Impact Passenger:

5 Stars

NHTSA Side Impact Front Seat:

5 Stars

NHTSA Side Impact Rear Seat:

5 Stars

NHTSA Rollover Rating:

4 Stars

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Electronic Stability:

Available Electronic Stability Program (ESP) / Stability Control

Passive Features

Airbags Front:

Driver and front-passenger airbags

Airbags Side:

Optional front-seat side-impact airbags

Airbags Overhead:

Optional roof-rail airbags (covering all three rows)

Seatbelts:

Three-point seat belts in all seating positions, front seatbelt pretensioners.

💡 Technology Features

Infotainment

Infotainment System:

Standard AM/FM stereo with CD player. Optional premium audio systems, rear-seat entertainment systems (DVD players), and navigation systems available on higher trims.

Driver Assistance

Driver Assistance Features:

Parking assist sensors (rear), rearview camera (optional on some trims).

Connectivity

Connectivity Options:

Optional SiriusXM Satellite Radio. No integrated Bluetooth or USB ports standard on this model year; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type. Refer to manual for exact schedule.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter Replacement:

Inspect/replace every 15,000 - 30,000 miles (24,000 - 48,000 km).

Spark Plug Replacement:

Approx. 100,000 miles (160,000 km) for recommended iridium spark plugs.

Transmission Fluid Service:

Every 30,000 - 60,000 miles (48,000 - 96,000 km). Consult manual for precise interval and method (flush vs. drain/fill).

Coolant Flush:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 3-5 years. Use correct OAT coolant.

Timing Belt Replacement:

The V6 engines used in this generation do NOT have a timing belt; they utilize a timing chain which is designed to last the life of the engine, though inspection for wear is still recommended by the manual.

Fluid Specifications

Engine Oil Type:

SAE 5W-20 (preferred) or SAE 5W-30. Check Owner's Manual and oil fill cap.

Engine Oil Capacity:

Approx. 5 quarts (4.7 Liters) with filter for 3.3L V6; Approx. 5 quarts (4.7 Liters) for 3.8L V6.

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or OAT (Organic Acid Technology) coolant. Typically orange or pink. Do NOT mix coolant types. Consult manual for specific color and type.

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 (Mopar) or equivalent, or specific power steering fluid as per manual.

Known Issues

Common Problems Engine:

Rear main seal leaks, intake manifold gasket leaks, occasional oil sludge buildup if maintenance is neglected.

Common Problems Transmission:

Torque converter shudder, transmission fluid leaks, transmission control module (TCM) issues, early failure of the 41TE transmission if not properly maintained.

Common Problems Suspension:

Worn sway bar links, ball joints, and control arm bushings leading to clunks and poor handling. Premature wear of struts/shocks.

Common Problems Brakes:

Warped brake rotors, premature wear of brake pads and calipers. ABS sensor issues can occur.

Common Problems Electrical:

Power window motor failures, issues with power sliding door mechanisms, headlight switch failures, alternator or starter issues.

Common Problems HVAC:

Blend door actuator failures, blower motor resistor failures, A/C compressor clutch issues, evaporator leaks.

📚 Vehicle History

Brand Heritage

Dodge Brand Identity:

Dodge, a division of Chrysler (now Stellantis), has a long history of producing robust and value-oriented vehicles, often targeting practical needs and performance.

Model Evolution

Caravan Generation:

Fourth Generation (NS), 2001-2007. The 2006 model year represents a mid-cycle refresh for this generation.

Key Changes For 2006:

Minor styling updates, potential feature packaging changes, continued refinement of existing powertrains.

Production

Production Location:

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

Parent Company:

DaimlerChrysler (at the time of production).

🏆 Awards & Recognition

Recognitions

Safety Awards:

Achieved 5-star ratings in NHTSA frontal and side impact crash tests for the 2006 model year, indicating strong safety performance.

Consumer Ratings:

Often praised for its practicality, space, and value. Can be subject to criticism regarding long-term reliability of certain powertrain components and interior materials compared to some competitors.

Certifications

Certification Type:

Factory Certified Repair Information