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DODGE CARAVAN 2003 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2003 Codes Platform: NS (Short Wheelbase), RS (Long Wheelbase) Chassis Code: CG (NS), GR (RS) 👋 Introduction Market Position Segment: Minivan Target Audience: DIY mechanics, professional technicians, fleet managers, owners seeking in-depth understanding Competitive Analysis Competitors 2003: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Plymouth Voyager/Grand Voyager Key Features Utility: Versatile seating configurations, ample cargo space, family-oriented features Powertrain Options: Known for its robust V6 engines and a less common diesel option in some markets 📋 Manual Details Coverage Areas Engine Options Covered: Gasoline and Diesel variants Page Count Estimated Pages: 1500+ Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, driveline, fuel system, exhaust system Chassis: Suspension, steering, brakes, wheels, tires Electrical: Body electrical, instrument cluster, lighting, starting and charging, infotainment, diagnostics Body And Trim: Interior and exterior trim, body panels, doors, windows, seats, HVAC system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Diagnostic charts, symptom-based troubleshooting, fault code explanations Repair: Component removal, installation, adjustment, and overhaul procedures Diagnostics: OBD-II diagnostics, sensor testing, actuator testing, wiring diagrams Technical Depth Depth: Comprehensive: from basic maintenance to complete engine and transmission overhauls, detailed electrical schematics 📊 Manual Specifications File Format Digital Format: PDF Print Quality Print Quality Considerations: Designed for digital use; printable pages can vary based on user's printer Binding Type Binding: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Gasoline Engine 1: 2.4L (2429cc) DOHC 16-valve I4 (Code: EDZ) Gasoline Engine 2: 3.3L (3301cc) OHV 12-valve V6 (Code: EGA) Gasoline Engine 3: 3.8L (3778cc) OHV 12-valve V6 (Code: ETR) Diesel Engine: 2.5L (2499cc) Turbocharged I4 Diesel (Code: R425) - Common in export markets Performance Gasoline 2.4L Hp: 150 hp @ 5800 rpm Gasoline 2.4L Torque: 160 lb-ft @ 4400 rpm Gasoline 3.3L Hp: 180 hp @ 5000 rpm Gasoline 3.3L Torque: 205 lb-ft @ 3600 rpm Gasoline 3.8L Hp: 215 hp @ 5000 rpm Gasoline 3.8L Torque: 240 lb-ft @ 3200 rpm Fuel System Gasoline Injection Type: Multi-port Fuel Injection (MPI) Diesel Injection Type: Direct Injection (Turbocharged) Fuel Type Recommended Gasoline: 87 Octane Regular Unleaded 🔧 Transmission Standard Transmission Gas 2.4L: 4-speed automatic (41TE) Transmission Gas 3.3L/3.8L: 4-speed automatic (42LE) Optional Transmission Diesel: 4-speed automatic (41TE or similar, market dependent) Features Shifter Location: Column-mounted Overdrive Gears: All 4-speed automatics feature overdrive 📐 Dimensions Exterior Wheelbase Ns: 111.9 inches Wheelbase Rs: 123.8 inches Length Ns: 189.8 inches Length Rs: 201.8 inches Width: 72.0 inches Height: 68.3 inches Cargo Cargo Volume Ns Max: Approx. 125.9 cu ft (with rear seats removed) Cargo Volume Rs Max: Approx. 159.5 cu ft (with rear seats removed) Weights Curb Weight Range: Approx. 3800 - 4300 lbs (depending on configuration) Towing Capacity: Up to 3800 lbs (with optional towing package and 3.8L engine) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 stars (2003 model year) NHTSA Front Impact Passenger: 4 stars (2003 model year) IIHS Frontal Offset: Acceptable (for models equipped with side airbags) Active Features ABS: Standard on all models Traction Control: Optional on some models Passive Features Airbags Front: Standard driver and front passenger airbags Airbags Side: Optional front and rear side-impact airbags Seat Belts: 3-point seat belts in all seating positions, front seat belt pretensioners 💡 Technology Features Infotainment Audio System Options: AM/FM stereo with CD player, cassette player; optional premium audio systems Rear Seat Entertainment: Optional rear-seat entertainment system (e.g., VCR or DVD player) Driver Assistance Cruise Control: Standard Parking Sensors: Optional rear parking assist system Connectivity Power Outlets: 12V power outlets in dashboard and rear seating areas 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 6 months, whichever comes first (depending on oil type and driving conditions) Air Filter Replacement: Inspect every 15,000 miles, replace as needed Spark Plug Replacement V6: Approx. 100,000 miles (Platinum or Iridium plugs) Transmission Fluid Change: Every 30,000-60,000 miles (check manual for specific intervals and fluid type) Fluid Specifications Engine Oil Type: SAE 5W-30 (API certified) Engine Oil Capacity 2.4L: Approx. 4.5 quarts (with filter) Engine Oil Capacity 3.3L/3.8L: Approx. 5.0 quarts (with filter) Coolant Type: Chrysler HOAT (Hybrid Organic Additive Technology) Extended Life Antifreeze/Coolant (e.g., Mopar 5 Year / 100,000 Mile Formula) Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid) Known Issues Power Window Motors: Known for premature failure of window regulator motors and switches. Transmission Overheating: Some models can experience transmission overheating, especially under heavy loads, often addressed by external coolers. Heater Core Leaks: Heater core can develop leaks, leading to coolant loss and fogging of the windshield. Wheel Bearings: Front wheel bearings can wear out prematurely. 📚 Vehicle History Brand Heritage Dodge Legacy: Dodge has a long history in American automotive manufacturing, often associated...
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DODGE CARAVAN 2003 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2003
Codes
Platform:
NS (Short Wheelbase), RS (Long Wheelbase)
Chassis Code:
CG (NS), GR (RS)
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
DIY mechanics, professional technicians, fleet managers, owners seeking in-depth understanding
Competitive Analysis
Competitors 2003:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Plymouth Voyager/Grand Voyager
Key Features
Utility:
Versatile seating configurations, ample cargo space, family-oriented features
Powertrain Options:
Known for its robust V6 engines and a less common diesel option in some markets
📋 Manual Details
Coverage Areas
Engine Options Covered:
Gasoline and Diesel variants
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, driveline, fuel system, exhaust system
Chassis:
Suspension, steering, brakes, wheels, tires
Electrical:
Body electrical, instrument cluster, lighting, starting and charging, infotainment, diagnostics
Body And Trim:
Interior and exterior trim, body panels, doors, windows, seats, HVAC system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, fault code explanations
Repair:
Component removal, installation, adjustment, and overhaul procedures
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, wiring diagrams
Technical Depth
Depth:
Comprehensive: from basic maintenance to complete engine and transmission overhauls, detailed electrical schematics
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Print Quality Considerations:
Designed for digital use; printable pages can vary based on user's printer
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Gasoline Engine 1:
2.4L (2429cc) DOHC 16-valve I4 (Code: EDZ)
Gasoline Engine 2:
3.3L (3301cc) OHV 12-valve V6 (Code: EGA)
Gasoline Engine 3:
3.8L (3778cc) OHV 12-valve V6 (Code: ETR)
Diesel Engine:
2.5L (2499cc) Turbocharged I4 Diesel (Code: R425) - Common in export markets
Performance
Gasoline 2.4L Hp:
150 hp @ 5800 rpm
Gasoline 2.4L Torque:
160 lb-ft @ 4400 rpm
Gasoline 3.3L Hp:
180 hp @ 5000 rpm
Gasoline 3.3L Torque:
205 lb-ft @ 3600 rpm
Gasoline 3.8L Hp:
215 hp @ 5000 rpm
Gasoline 3.8L Torque:
240 lb-ft @ 3200 rpm
Fuel System
Gasoline Injection Type:
Multi-port Fuel Injection (MPI)
Diesel Injection Type:
Direct Injection (Turbocharged)
Fuel Type
Recommended Gasoline:
87 Octane Regular Unleaded
🔧 Transmission
Standard
Transmission Gas 2.4L:
4-speed automatic (41TE)
Transmission Gas 3.3L/3.8L:
4-speed automatic (42LE)
Optional
Transmission Diesel:
4-speed automatic (41TE or similar, market dependent)
Features
Shifter Location:
Column-mounted
Overdrive Gears:
All 4-speed automatics feature overdrive
📐 Dimensions
Exterior
Wheelbase Ns:
111.9 inches
Wheelbase Rs:
123.8 inches
Length Ns:
189.8 inches
Length Rs:
201.8 inches
Width:
72.0 inches
Height:
68.3 inches
Cargo
Cargo Volume Ns Max:
Approx. 125.9 cu ft (with rear seats removed)
Cargo Volume Rs Max:
Approx. 159.5 cu ft (with rear seats removed)
Weights
Curb Weight Range:
Approx. 3800 - 4300 lbs (depending on configuration)
Towing Capacity:
Up to 3800 lbs (with optional towing package and 3.8L engine)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 stars (2003 model year)
NHTSA Front Impact Passenger:
4 stars (2003 model year)
IIHS Frontal Offset:
Acceptable (for models equipped with side airbags)
Active Features
ABS:
Standard on all models
Traction Control:
Optional on some models
Passive Features
Airbags Front:
Standard driver and front passenger airbags
Airbags Side:
Optional front and rear side-impact airbags
Seat Belts:
3-point seat belts in all seating positions, front seat belt pretensioners
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with CD player, cassette player; optional premium audio systems
Rear Seat Entertainment:
Optional rear-seat entertainment system (e.g., VCR or DVD player)
Driver Assistance
Cruise Control:
Standard
Parking Sensors:
Optional rear parking assist system
Connectivity
Power Outlets:
12V power outlets in dashboard and rear seating areas
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first (depending on oil type and driving conditions)
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed
Spark Plug Replacement V6:
Approx. 100,000 miles (Platinum or Iridium plugs)
Transmission Fluid Change:
Every 30,000-60,000 miles (check manual for specific intervals and fluid type)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API certified)
Engine Oil Capacity 2.4L:
Approx. 4.5 quarts (with filter)
Engine Oil Capacity 3.3L/3.8L:
Approx. 5.0 quarts (with filter)
Coolant Type:
Chrysler HOAT (Hybrid Organic Additive Technology) Extended Life Antifreeze/Coolant (e.g., Mopar 5 Year / 100,000 Mile Formula)
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid)
Known Issues
Power Window Motors:
Known for premature failure of window regulator motors and switches.
Transmission Overheating:
Some models can experience transmission overheating, especially under heavy loads, often addressed by external coolers.
Heater Core Leaks:
Heater core can develop leaks, leading to coolant loss and fogging of the windshield.
Wheel Bearings:
Front wheel bearings can wear out prematurely.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history in American automotive manufacturing, often associated with performance and utility vehicles.
Model Evolution
Caravan Lineage:
The Dodge Caravan, along with its Plymouth Voyager sibling, pioneered the minivan segment in the early 1980s.
Third Generation:
The 2003 model belongs to the third generation of the Caravan (1996-2007), characterized by a more aerodynamic design and improved interior packaging.
Production
Manufacturing Plant:
Windsor, Ontario, Canada (primarily)
Production Years Generation:
1996-2007
🏆 Awards & Recognition
Recognitions
Berkaitan Awards:
Frequently appeared on 'Car and Driver' 10 Best lists in its earlier iterations. The 2003 model benefited from continuous refinements.
Ratings
Consumer Reports Reliability Tendency:
Generally rated average to below average in reliability for this generation, particularly concerning certain powertrain and electrical components. Manual is crucial for addressing these.
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