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CHRYSLER CARAVAN 2003-2007 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Year Range: 2003-2007 Codes Platform: NS 👋 Introduction Market Position Segment: Minivan (Family/Utility Vehicle) Competitive Analysis Key Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Monterey Key Features Vehicle Strengths: Spacious interior, versatile seating arrangements, Stow 'n Go seating (later models), comfortable ride, family-friendly features. Manual Value Proposition: Provides professional-level diagnostic and repair procedures, empowering owners and independent repair shops to maintain and fix the vehicle effectively. 📋 Manual Details Coverage Areas Coverage: Full Service and Repair Page Count Estimated Pages: 1500+ Manual Type Type: Professional Technical Service Manual Language Language: English Format Format: Digital (likely PDF, searchable) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, starting, charging Transmission Drivetrain: Automatic transmission overhaul, service, diagnostics, driveline, axles, CV joints Suspension Steering: Front and rear suspension components, steering gear, power steering system Brakes: Hydraulic brake system, ABS, power assist, parking brake Electrical Electronics: Battery, starting, charging, lighting, instruments, fuses, relays, body control module (BCM), comfort features HVAC: Heating, ventilation, and air conditioning system diagnostics and repair Body Chassis: Body panels, doors, windows, interior trim, bumpers, frame and underbody Procedures Included Maintenance: Routine maintenance schedules, fluid changes, filter replacements, tune-ups Diagnostics: Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation Repair Overhaul: Step-by-step repair procedures for major components, complete engine and transmission rebuilds Specifications Tolerances: Torque specifications, clearances, alignment angles, electrical specifications Technical Depth Depth: Comprehensive: Covers basic maintenance to complex diagnostic and repair procedures, including component-level troubleshooting. 📊 Manual Specifications File Format Digital Quality: High-resolution, searchable text for efficient navigation and information retrieval. Print Quality Printable: Designed for printing specific sections or the entire manual for workshop use. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type 1: 3.3L V6 (203 CID) Engine Code 1: EGA Horsepower 1: 180 hp @ 5000 rpm (approx.) Torque 1: 205 lb-ft @ 4000 rpm (approx.) Secondary Engine Engine Type 2: 3.8L V6 (230 CID) Engine Code 2: L32 Horsepower 2: 200-215 hp @ 5000 rpm (approx.) Torque 2: 230-240 lb-ft @ 4000 rpm (approx.) Performance Fuel Type: Unleaded Gasoline Fuel System Induction Type: Multi-point fuel injection (MPI) Technical Details Block Material: Cast Iron Cylinder Head Material: Aluminum Valvetrain: Overhead Valve (OHV), 12 valves (2 per cylinder) 🔧 Transmission Standard Transmission Type Standard: 4-speed Automatic Transaxle Optional Transmission Type Optional: N/A (All models used automatic) Features Transmission Features: Electronically controlled, torque converter lock-up for improved efficiency. Fluid Specifications Transmission Fluid Type: Chrysler ATF+4 (or equivalent specification) 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 196.5 inches (5000 mm) Width: 76.7 inches (1948 mm) Height: 68.0 inches (1727 mm) Cargo Cargo Volume Behind 3Rd Row: Approx. 20-30 cu ft (depending on configuration) Cargo Volume Behind 2Nd Row: Approx. 80-90 cu ft (depending on configuration) Cargo Volume With All Seats Folded: Approx. 140-160 cu ft (depending on configuration) Weights Curb Weight: Approx. 4000-4400 lbs (1814-1996 kg) Gross Vehicle Weight Rating Gvw: Approx. 5700-6000 lbs (2585-2722 kg) Towing Capacity: Up to 3800 lbs (1724 kg) with optional towing package 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for its era, but later models improved) NHTSA Front Impact Passenger: Good (for its era) IIHS Moderate Overlap Frontal Offset: Acceptable (for 2005-2007 models with structural improvements) Active Features ABS: Standard on most models, optional on some base trims. Traction Control: Optional on select models, often paired with ABS. Passive Features Airbags Front: Driver and front passenger airbags standard. Airbags Side: Optional front-seat side airbags on some trims. Seatbelts: Three-point seatbelts for all seating positions, including integrated child seat anchors. 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette, satellite radio compatibility. Premium Infinity sound systems available on higher trims. Navigation: Optional factory navigation system available on some higher-trim models (late in the production run). Driver Assistance Cruise Control: Standard on most models. Connectivity Power Features: Power windows, power door locks, power sliding doors (optional on some trims), power liftgate (optional on some trims). Comfort Features Seating: Configurable seating for 7 or 8 passengers. Available captain's chairs, Stow 'n Go foldable seats (from 2005 onwards). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendations). Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) Spark Plug Replacement: Every 30,000-100,000 miles (48,000-160,000 km) depending on spark plug type (e.g., copper vs. platinum/iridium). Transmission Fluid Service: Every 30,000-60,000 miles (48,000-96,000 km), recommended by manual or based on fluid condition. Fluid Specifications Engine Oil Type: SAE 5W-30 (preferred), SAE 10W-30 acceptable for 3.3L; SAE 5W-30 for 3.8L. Check owner's manual or oil cap for specific viscosity and API certification (e.g., API SN/SP). Coolant...
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CHRYSLER CARAVAN 2003-2007 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Year Range:
2003-2007
Codes
Platform:
NS
👋 Introduction
Market Position
Segment:
Minivan (Family/Utility Vehicle)
Competitive Analysis
Key Competitors:
Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Monterey
Key Features
Vehicle Strengths:
Spacious interior, versatile seating arrangements, Stow 'n Go seating (later models), comfortable ride, family-friendly features.
Manual Value Proposition:
Provides professional-level diagnostic and repair procedures, empowering owners and independent repair shops to maintain and fix the vehicle effectively.
📋 Manual Details
Coverage Areas
Coverage:
Full Service and Repair
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Professional Technical Service Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, searchable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, starting, charging
Transmission Drivetrain:
Automatic transmission overhaul, service, diagnostics, driveline, axles, CV joints
Suspension Steering:
Front and rear suspension components, steering gear, power steering system
Brakes:
Hydraulic brake system, ABS, power assist, parking brake
Electrical Electronics:
Battery, starting, charging, lighting, instruments, fuses, relays, body control module (BCM), comfort features
HVAC:
Heating, ventilation, and air conditioning system diagnostics and repair
Body Chassis:
Body panels, doors, windows, interior trim, bumpers, frame and underbody
Procedures Included
Maintenance:
Routine maintenance schedules, fluid changes, filter replacements, tune-ups
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation
Repair Overhaul:
Step-by-step repair procedures for major components, complete engine and transmission rebuilds
Specifications Tolerances:
Torque specifications, clearances, alignment angles, electrical specifications
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to complex diagnostic and repair procedures, including component-level troubleshooting.
📊 Manual Specifications
File Format
Digital Quality:
High-resolution, searchable text for efficient navigation and information retrieval.
Print Quality
Printable:
Designed for printing specific sections or the entire manual for workshop use.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
3.3L V6 (203 CID)
Engine Code 1:
EGA
Horsepower 1:
180 hp @ 5000 rpm (approx.)
Torque 1:
205 lb-ft @ 4000 rpm (approx.)
Secondary Engine
Engine Type 2:
3.8L V6 (230 CID)
Engine Code 2:
L32
Horsepower 2:
200-215 hp @ 5000 rpm (approx.)
Torque 2:
230-240 lb-ft @ 4000 rpm (approx.)
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Induction Type:
Multi-point fuel injection (MPI)
Technical Details
Block Material:
Cast Iron
Cylinder Head Material:
Aluminum
Valvetrain:
Overhead Valve (OHV), 12 valves (2 per cylinder)
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic Transaxle
Optional
Transmission Type Optional:
N/A (All models used automatic)
Features
Transmission Features:
Electronically controlled, torque converter lock-up for improved efficiency.
Fluid Specifications
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification)
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
196.5 inches (5000 mm)
Width:
76.7 inches (1948 mm)
Height:
68.0 inches (1727 mm)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20-30 cu ft (depending on configuration)
Cargo Volume Behind 2Nd Row:
Approx. 80-90 cu ft (depending on configuration)
Cargo Volume With All Seats Folded:
Approx. 140-160 cu ft (depending on configuration)
Weights
Curb Weight:
Approx. 4000-4400 lbs (1814-1996 kg)
Gross Vehicle Weight Rating Gvw:
Approx. 5700-6000 lbs (2585-2722 kg)
Towing Capacity:
Up to 3800 lbs (1724 kg) with optional towing package
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for its era, but later models improved)
NHTSA Front Impact Passenger:
Good (for its era)
IIHS Moderate Overlap Frontal Offset:
Acceptable (for 2005-2007 models with structural improvements)
Active Features
ABS:
Standard on most models, optional on some base trims.
Traction Control:
Optional on select models, often paired with ABS.
Passive Features
Airbags Front:
Driver and front passenger airbags standard.
Airbags Side:
Optional front-seat side airbags on some trims.
Seatbelts:
Three-point seatbelts for all seating positions, including integrated child seat anchors.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette, satellite radio compatibility. Premium Infinity sound systems available on higher trims.
Navigation:
Optional factory navigation system available on some higher-trim models (late in the production run).
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Power Features:
Power windows, power door locks, power sliding doors (optional on some trims), power liftgate (optional on some trims).
Comfort Features
Seating:
Configurable seating for 7 or 8 passengers. Available captain's chairs, Stow 'n Go foldable seats (from 2005 onwards).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km)
Spark Plug Replacement:
Every 30,000-100,000 miles (48,000-160,000 km) depending on spark plug type (e.g., copper vs. platinum/iridium).
Transmission Fluid Service:
Every 30,000-60,000 miles (48,000-96,000 km), recommended by manual or based on fluid condition.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (preferred), SAE 10W-30 acceptable for 3.3L; SAE 5W-30 for 3.8L. Check owner's manual or oil cap for specific viscosity and API certification (e.g., API SN/SP).
Coolant Type:
Chrysler/Mopar Antifreeze/Coolant (AF) 5/10 Year Formula or equivalent HOAT (Hybrid Organic Acid Technology) coolant.
Brake Fluid Type:
DOT 3
Known Issues
Common Problems Powertrain:
Transmission solenoid failures, head gasket leaks (especially on 3.3L), intake manifold gasket leaks, oil filter housing leaks.
Common Problems Electrical:
Instrument cluster failures, power window motor failures, BCM issues, rear wiper motor failures.
Common Problems Suspension Steering:
Worn front suspension components (ball joints, tie rod ends), power steering pump whine or leaks, strut mounts.
Common Problems Body:
Rear liftgate struts weak, rust in wheel wells and rocker panels, sliding door track issues.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. The Chrysler Caravan is the direct successor.
Model Evolution
Generation Context:
These models represent the third generation (NS) of the Chrysler minivan, which saw significant updates and refreshes throughout its production. This manual covers the later part of this generation.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Key Updates 2003-2007:
Structural improvements for crashworthiness, updated styling, introduction of Stow 'n Go seating (2005 model year), improved powertrain options, enhanced safety features.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
Chrysler minivans frequently appeared on Car and Driver's Ten Best lists during this era due to their innovation and market dominance.
Ratings
Consumer Reports:
Ratings varied by year, but generally positioned as a competitive and practical choice in the minivan segment, with specific praise for interior space and versatility. Common issues like transmission reliability were noted.
Certifications
Industry Standard Compliance:
The manual adheres to industry standards for technical documentation, providing accurate procedures and specifications for safe and effective vehicle maintenance and repair.
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