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Chrysler Town&Country 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Town & Country Year: 2003 Codes Chassis Code: RG 👋 Introduction Market Position Vehicle Segment: Full-size minivan Target Audience: Families requiring spacious and versatile transportation Competitive Analysis Key Competitors: Dodge Grand Caravan, Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar Key Features Innovations At Time: Stow 'n Go seating (introduced later in the generation but concept of minivan flexibility was key) Manual Value Proposition: Empowers owners and technicians with factory-level diagnostic and repair knowledge for accurate and efficient servicing. 📋 Manual Details Coverage Areas Applicable Models: All 2003 Chrysler Town & Country trims and configurations Page Count Estimated Page Count: Approx. 2000-3000 pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, component testing, specifications for all engines Engine Electrical: Ignition system, fuel injection, sensors, actuators, diagnostics, wiring diagrams Transmission Mechanical: Automatic transmission (e.g., 41TE/42LE) overhaul, component identification, torque specifications Transmission Electrical: Transmission control module (TCM) diagnostics, sensor inputs, solenoid operation, wiring diagrams Brakes: Hydraulic system, ABS (Anti-lock Braking System), components, bleeding procedures, diagnostics Suspension: Front and rear suspension components, alignment specifications, troubleshooting Steering: Power steering system, steering gear, components, fluid specifications HVAC: Heating, Ventilation, and Air Conditioning system, refrigerant handling, component diagnosis Body Electrical: Lighting, power accessories, interior/exterior electronics, control modules, wiring diagrams Body Structure: Body panel removal/installation, structural components, door/window mechanisms Chassis Electrical: Trailer wiring, towing provisions, chassis sensors Procedures Included Routine Maintenance: Oil change, filter replacement, fluid checks, spark plug service, belt replacement Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, flowcharts Component Replacement: Detailed step-by-step instructions for replacing major and minor components Disassembly Assembly: Comprehensive guides for breaking down and reassembling vehicle systems and components Diagnostic Testing: Procedures for testing electrical circuits, sensors, actuators, and mechanical systems Torque Specifications: Precise torque values for all critical fasteners Alignment Procedures: Front and rear wheel alignment specifications and adjustment procedures Technical Depth Diagnostic Capabilities: In-depth diagnostic procedures, including OBD-II interpretation and specific Chrysler diagnostic tools Repair Complexity: Covers everything from basic fluid changes to complete engine and transmission rebuilds Electrical Diagrams: Detailed, high-quality wiring diagrams for all vehicle systems Component Illustrations: Clear illustrations and diagrams of components and their locations 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Printability: Printable pages for workshop use Print Quality Resolution: High-resolution scans/digital files for clarity Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: EGW Engine Type: 3.3L V6 SOHC MPI Displacement: 3301 cc (201.5 cubic inches) Bore X Stroke: 93.0 mm x 81.0 mm (3.66 in x 3.19 in) Compression Ratio: 9.6:1 Performance Horsepower: 180 hp @ 5000 RPM Torque: 205 lb-ft @ 3200 RPM Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Fuel Pump Pressure: 49-57 PSI (338-393 kPa) Engine Code Optional Engine Code: EGQ Optional Engine Code Optional Engine Type: 3.8L V6 OHV MPI Optional Engine Type Optional Displacement: 3800 cc (231.9 cubic inches) Optional Performance Optional Horsepower: 205 hp @ 5000 RPM Optional Torque: 240 lb-ft @ 3000 RPM 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle Transmission Model: 41TE Optional Transmission Type Optional: 4-speed Automatic Transaxle Transmission Model Optional: 42LE (typically with the 3.8L engine) Features Overdrive Gears: 4 (including overdrive) Transmission Fluid Type: ATF+4 (Mopar) Transmission Fluid Capacity: Approx. 8.0 quarts (7.6 liters) for refill, 10.5 quarts (9.9 liters) for overhaul 📐 Dimensions Exterior Wheelbase: 3030 mm (119.3 inches) Length: 4999 mm (196.8 inches) Width: 1943 mm (76.5 inches) Height: 1750 mm (68.9 inches) Front Track: 1600 mm (63.0 inches) Rear Track: 1608 mm (63.3 inches) Cargo Cargo Volume Behind 3Rd Row: Approx. 0.4 cubic meters (14.1 cubic feet) Cargo Volume Behind 2Nd Row: Approx. 1.3 cubic meters (45.1 cubic feet) Cargo Volume Behind 1St Row: Approx. 3.0 cubic meters (106.1 cubic feet) Weights Curb Weight: Approx. 1900-2000 kg (4200-4400 lbs) Gross Vehicle Weight Rating Gvwr: Approx. 2722 kg (6000 lbs) Towing Capacity: 3500 lbs (1588 kg) with optional towing package 🛡️ Safety Features Ratings NHTSA Front Driver Impact: 5-star (2003 Model Year) NHTSA Front Passenger Impact: 5-star (2003 Model Year) NHTSA Side Driver Impact: 4-star (2003 Model Year) NHTSA Side Passenger Impact: 4-star (2003 Model Year) NHTSA Rollover Resistance: 4-star (2003 Model Year) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Available front-seat side airbags Seatbelts: Three-point seat belts with pretensioners for all seating positions 💡 Technology Features Infotainment Audio System: Available AM/FM stereo with CD player, optional Infinity speaker systems, and rear-seat entertainment options. Driver Assistance Parking Assist: Optional rear parking assist sensors....
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Chrysler Town&Country 2003 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Town & Country
Year:
2003
Codes
Chassis Code:
RG
👋 Introduction
Market Position
Vehicle Segment:
Full-size minivan
Target Audience:
Families requiring spacious and versatile transportation
Competitive Analysis
Key Competitors:
Dodge Grand Caravan, Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar
Key Features
Innovations At Time:
Stow 'n Go seating (introduced later in the generation but concept of minivan flexibility was key)
Manual Value Proposition:
Empowers owners and technicians with factory-level diagnostic and repair knowledge for accurate and efficient servicing.
📋 Manual Details
Coverage Areas
Applicable Models:
All 2003 Chrysler Town & Country trims and configurations
Page Count
Estimated Page Count:
Approx. 2000-3000 pages (typical for comprehensive factory service manuals)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures, component testing, specifications for all engines
Engine Electrical:
Ignition system, fuel injection, sensors, actuators, diagnostics, wiring diagrams
Transmission Mechanical:
Automatic transmission (e.g., 41TE/42LE) overhaul, component identification, torque specifications
Transmission Electrical:
Transmission control module (TCM) diagnostics, sensor inputs, solenoid operation, wiring diagrams
Brakes:
Hydraulic system, ABS (Anti-lock Braking System), components, bleeding procedures, diagnostics
Suspension:
Front and rear suspension components, alignment specifications, troubleshooting
Steering:
Power steering system, steering gear, components, fluid specifications
HVAC:
Heating, Ventilation, and Air Conditioning system, refrigerant handling, component diagnosis
Body Electrical:
Lighting, power accessories, interior/exterior electronics, control modules, wiring diagrams
Body Structure:
Body panel removal/installation, structural components, door/window mechanisms
Chassis Electrical:
Trailer wiring, towing provisions, chassis sensors
Procedures Included
Routine Maintenance:
Oil change, filter replacement, fluid checks, spark plug service, belt replacement
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, flowcharts
Component Replacement:
Detailed step-by-step instructions for replacing major and minor components
Disassembly Assembly:
Comprehensive guides for breaking down and reassembling vehicle systems and components
Diagnostic Testing:
Procedures for testing electrical circuits, sensors, actuators, and mechanical systems
Torque Specifications:
Precise torque values for all critical fasteners
Alignment Procedures:
Front and rear wheel alignment specifications and adjustment procedures
Technical Depth
Diagnostic Capabilities:
In-depth diagnostic procedures, including OBD-II interpretation and specific Chrysler diagnostic tools
Repair Complexity:
Covers everything from basic fluid changes to complete engine and transmission rebuilds
Electrical Diagrams:
Detailed, high-quality wiring diagrams for all vehicle systems
Component Illustrations:
Clear illustrations and diagrams of components and their locations
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Printability:
Printable pages for workshop use
Print Quality
Resolution:
High-resolution scans/digital files for clarity
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EGW
Engine Type:
3.3L V6 SOHC MPI
Displacement:
3301 cc (201.5 cubic inches)
Bore X Stroke:
93.0 mm x 81.0 mm (3.66 in x 3.19 in)
Compression Ratio:
9.6:1
Performance
Horsepower:
180 hp @ 5000 RPM
Torque:
205 lb-ft @ 3200 RPM
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Fuel Pump Pressure:
49-57 PSI (338-393 kPa)
Engine Code
Optional Engine Code:
EGQ
Optional Engine Code
Optional Engine Type:
3.8L V6 OHV MPI
Optional Engine Type
Optional Displacement:
3800 cc (231.9 cubic inches)
Optional Performance
Optional Horsepower:
205 hp @ 5000 RPM
Optional Torque:
240 lb-ft @ 3000 RPM
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle
Transmission Model:
41TE
Optional
Transmission Type Optional:
4-speed Automatic Transaxle
Transmission Model Optional:
42LE (typically with the 3.8L engine)
Features
Overdrive Gears:
4 (including overdrive)
Transmission Fluid Type:
ATF+4 (Mopar)
Transmission Fluid Capacity:
Approx. 8.0 quarts (7.6 liters) for refill, 10.5 quarts (9.9 liters) for overhaul
📐 Dimensions
Exterior
Wheelbase:
3030 mm (119.3 inches)
Length:
4999 mm (196.8 inches)
Width:
1943 mm (76.5 inches)
Height:
1750 mm (68.9 inches)
Front Track:
1600 mm (63.0 inches)
Rear Track:
1608 mm (63.3 inches)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 0.4 cubic meters (14.1 cubic feet)
Cargo Volume Behind 2Nd Row:
Approx. 1.3 cubic meters (45.1 cubic feet)
Cargo Volume Behind 1St Row:
Approx. 3.0 cubic meters (106.1 cubic feet)
Weights
Curb Weight:
Approx. 1900-2000 kg (4200-4400 lbs)
Gross Vehicle Weight Rating Gvwr:
Approx. 2722 kg (6000 lbs)
Towing Capacity:
3500 lbs (1588 kg) with optional towing package
🛡️ Safety Features
Ratings
NHTSA Front Driver Impact:
5-star (2003 Model Year)
NHTSA Front Passenger Impact:
5-star (2003 Model Year)
NHTSA Side Driver Impact:
4-star (2003 Model Year)
NHTSA Side Passenger Impact:
4-star (2003 Model Year)
NHTSA Rollover Resistance:
4-star (2003 Model Year)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Available front-seat side airbags
Seatbelts:
Three-point seat belts with pretensioners for all seating positions
💡 Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, optional Infinity speaker systems, and rear-seat entertainment options.
Driver Assistance
Parking Assist:
Optional rear parking assist sensors.
Connectivity
Remote Keyless Entry:
Standard or optional remote keyless entry system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (with synthetic blend or synthetic oil)
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km)
Cabin Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km)
Spark Plugs:
Replace at 100,000 miles (160,000 km) (typically platinum or iridium type)
Transmission Fluid:
Inspect every 30,000 miles (48,000 km), replace fluid and filter every 60,000 miles (96,000 km)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API Certified)
Engine Oil Capacity:
4.75 quarts (4.5 liters) with filter (3.3L engine), 5.0 quarts (4.7 liters) with filter (3.8L engine)
Coolant Type:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (MS-9769)
Coolant Capacity:
Approx. 10.5 quarts (9.9 liters)
Brake Fluid Type:
DOT 3
Power Steering Fluid:
ATF+4 (Mopar) or equivalent
Known Issues
Common Transmission Issue:
Slipping or harsh shifting due to internal wear or solenoid issues in the 41TE/42LE transmissions.
Common Engine Issue:
Intake manifold gasket leaks (particularly on the 3.8L OHV engine) leading to coolant or vacuum leaks.
Common Electrical Issue:
Power sliding door module failures, power window regulator issues, and occasional HVAC control module problems.
Common Suspension Issue:
Worn ball joints, tie rod ends, and control arm bushings leading to steering looseness and tire wear.
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler has a long history of innovation in the minivan segment, pioneering the concept.
Model Evolution
Generation:
Third Generation (2001-2007)
Design Language:
More rounded and aerodynamic styling compared to previous generations.
Key Updates 2003:
Minor updates, potentially including new option packages or feature availability.
Production
Manufacturing Plant:
Windsor Assembly Plant, Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Chrysler's minivans have consistently been strong sellers and popular choices in their segment.
Safety Awards:
Achieved good NHTSA ratings, reflecting a focus on occupant safety for the era.
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