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Dodge Caravan 2003 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2003 👋 Introduction Market Position Segment: Minivan Target Audience: Families, commercial use Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture Key Features Versatility: Known for its flexible seating arrangements and cargo space. Practicality: Designed for everyday family needs and hauling capabilities. Affordability: Often positioned as a more budget-friendly option in its class. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Brakes: Yes Suspension: Yes Steering: Yes Electrical System: Yes Body And Frame: Yes HVAC: Yes Interior Trim: Yes Diagnostics And Troubleshooting: Yes Maintenance Procedures: Yes Component Replacement: Yes Wiring Diagrams: Yes Page Count Approximate Pages: 2000+ Manual Type Type: Factory Service Manual Purpose: Repair and Maintenance Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for all engine variants, including cylinder head, block, pistons, crankshaft, camshafts, timing, and lubrication systems. Engine Performance: Detailed diagnostics for fuel delivery, ignition system, emissions control, cooling system, and starting/charging systems. Transmission Automatic: Diagnosis, overhaul, and adjustment procedures for the automatic transmission (e.g., 41TE/42LE). Transmission Manual: Diagnosis and repair procedures for any manual transmission options if available. Brake System: Disc brake overhaul (front and rear), drum brake maintenance (rear), hydraulic system diagnostics, parking brake adjustments. Suspension System: Front and rear suspension component diagnosis and replacement (struts, shocks, ball joints, control arms, bushings), wheel alignment specifications. Steering System: Power steering system diagnosis and repair, steering gear/rack and pinion overhaul, steering column components. Electrical System Power Distribution: Battery, charging system, starter motor, fuses, relays, and power distribution modules. Electrical System Lighting: Headlights, taillights, interior lighting, hazard lights, and related circuits. Electrical System Instrumentation: Instrument cluster diagnosis and repair, gauge functionality. Body Exterior: Door mechanisms, latches, hinges, glass replacement, exterior trim, bumpers. Body Interior: Seat removal and repair, interior trim panel removal, dashboard disassembly, headliner. HVAC System: Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser, heater core replacement, blower motor. Safety Systems: Airbag system diagnosis and component replacement, seat belt mechanisms. Procedures Included Preventive Maintenance: Scheduled maintenance intervals for oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement, belt inspections. Diagnostic Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting trees. Component Repair And Rebuild: Detailed instructions for disassembling, inspecting, repairing, and reassembling major components like engines, transmissions, brakes, and steering racks. Electrical Diagnostics: Wiring diagrams, circuit testing procedures, component testing methods, and diagnostic trouble code (DTC) interpretation. Body Repair: Panel replacement, dent repair, door and glass repair procedures. Lubrication And Capacities: Specific fluid types, capacities, and lubrication points for all vehicle systems. Technical Depth Depth: Comprehensive from basic fluid changes to complete engine and transmission overhauls, including advanced electrical diagnostics and bodywork. 📊 Manual Specifications File Format Format: PDF Searchable Text: Yes Printable: Yes Print Quality Quality: High-resolution scans, clear diagrams and text. Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code 1: ECL (2.4L GEMA I4) Displacement 1: 2.4 Liters Horsepower 1: 150 hp @ 5600 rpm Torque 1: 170 lb-ft @ 4000 rpm Secondary Engine Engine Code 2: ESR (3.3L EER V6) Displacement 2: 3.3 Liters Horsepower 2: 180 hp @ 5000 rpm Torque 2: 205 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Emission Control: California Emissions System (Optional on some models) 🔧 Transmission Standard Transmission Type 1: 4-Speed Automatic (41TE/42LE) Optional Transmission Type 2: 5-Speed Manual (Rare, if available for specific configurations) Features Transmission Fluid Type: ATF+4 (Mopar) Transmission Fluid Capacity: Approximately 10.4 quarts (9.8 liters) for initial fill 📐 Dimensions Exterior Wheelbase: 112.1 inches (2847 mm) Length: 187.4 inches (4760 mm) Width: 72.4 inches (1839 mm) Height: 67.2 inches (1707 mm) Cargo Cargo Volume Max: 143.7 cubic feet (4069 liters) Weights Curb Weight Min: Approximately 3800 lbs (1724 kg) Gross Vehicle Weight Rating Gvwr: Approximately 5600 lbs (2540 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: ★★★★☆ (4/5 Stars) NHTSA Front Impact Passenger: ★★★★☆ (4/5 Stars) NHTSA Side Impact Front Driver: ★★★★☆ (4/5 Stars) NHTSA Side Impact Rear Passenger: ★★★★☆ (4/5 Stars) Active Features ABS: Standard on all models Traction Control: Optional on some models Passive Features Airbags Front: Driver and Passenger Frontal Airbags Airbags Side: Optional Side Curtain Airbags (availability varies by trim) Seatbelts: Three-point seat belts for all seating positions 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette and/or CD player, optional CD changer. Display: Basic digital or analog displays for radio and climate controls. Driver Assistance Cruise Control: Standard on most trims Rear Parking Sensors: Optional availability Connectivity Auxiliary Input: Not typically standard, may be aftermarket modification Bluetooth: Not available from factory 🔧 Maintenance Service Intervals Oil Change Interval Severe: 3,000 miles (4,800 km) or 3 months Oil Change Interval Normal: 7,500 miles...
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Mots clés: 2003 Car Caravan Cars Dodge Misc
Dodge Caravan 2003 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2003
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Families, commercial use
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Versatility:
Known for its flexible seating arrangements and cargo space.
Practicality:
Designed for everyday family needs and hauling capabilities.
Affordability:
Often positioned as a more budget-friendly option in its class.
📋 Manual Details
Coverage Areas
Engine:
Yes
Transmission:
Yes
Brakes:
Yes
Suspension:
Yes
Steering:
Yes
Electrical System:
Yes
Body And Frame:
Yes
HVAC:
Yes
Interior Trim:
Yes
Diagnostics And Troubleshooting:
Yes
Maintenance Procedures:
Yes
Component Replacement:
Yes
Wiring Diagrams:
Yes
Page Count
Approximate Pages:
2000+
Manual Type
Type:
Factory Service Manual
Purpose:
Repair and Maintenance
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures for all engine variants, including cylinder head, block, pistons, crankshaft, camshafts, timing, and lubrication systems.
Engine Performance:
Detailed diagnostics for fuel delivery, ignition system, emissions control, cooling system, and starting/charging systems.
Transmission Automatic:
Diagnosis, overhaul, and adjustment procedures for the automatic transmission (e.g., 41TE/42LE).
Transmission Manual:
Diagnosis and repair procedures for any manual transmission options if available.
Brake System:
Disc brake overhaul (front and rear), drum brake maintenance (rear), hydraulic system diagnostics, parking brake adjustments.
Suspension System:
Front and rear suspension component diagnosis and replacement (struts, shocks, ball joints, control arms, bushings), wheel alignment specifications.
Steering System:
Power steering system diagnosis and repair, steering gear/rack and pinion overhaul, steering column components.
Electrical System Power Distribution:
Battery, charging system, starter motor, fuses, relays, and power distribution modules.
Electrical System Lighting:
Headlights, taillights, interior lighting, hazard lights, and related circuits.
Electrical System Instrumentation:
Instrument cluster diagnosis and repair, gauge functionality.
Body Exterior:
Door mechanisms, latches, hinges, glass replacement, exterior trim, bumpers.
Body Interior:
Seat removal and repair, interior trim panel removal, dashboard disassembly, headliner.
HVAC System:
Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser, heater core replacement, blower motor.
Safety Systems:
Airbag system diagnosis and component replacement, seat belt mechanisms.
Procedures Included
Preventive Maintenance:
Scheduled maintenance intervals for oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement, belt inspections.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting trees.
Component Repair And Rebuild:
Detailed instructions for disassembling, inspecting, repairing, and reassembling major components like engines, transmissions, brakes, and steering racks.
Electrical Diagnostics:
Wiring diagrams, circuit testing procedures, component testing methods, and diagnostic trouble code (DTC) interpretation.
Body Repair:
Panel replacement, dent repair, door and glass repair procedures.
Lubrication And Capacities:
Specific fluid types, capacities, and lubrication points for all vehicle systems.
Technical Depth
Depth:
Comprehensive from basic fluid changes to complete engine and transmission overhauls, including advanced electrical diagnostics and bodywork.
📊 Manual Specifications
File Format
Format:
PDF
Searchable Text:
Yes
Printable:
Yes
Print Quality
Quality:
High-resolution scans, clear diagrams and text.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
ECL (2.4L GEMA I4)
Displacement 1:
2.4 Liters
Horsepower 1:
150 hp @ 5600 rpm
Torque 1:
170 lb-ft @ 4000 rpm
Secondary Engine
Engine Code 2:
ESR (3.3L EER V6)
Displacement 2:
3.3 Liters
Horsepower 2:
180 hp @ 5000 rpm
Torque 2:
205 lb-ft @ 3600 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Emission Control:
California Emissions System (Optional on some models)
🔧 Transmission
Standard
Transmission Type 1:
4-Speed Automatic (41TE/42LE)
Optional
Transmission Type 2:
5-Speed Manual (Rare, if available for specific configurations)
Features
Transmission Fluid Type:
ATF+4 (Mopar)
Transmission Fluid Capacity:
Approximately 10.4 quarts (9.8 liters) for initial fill
📐 Dimensions
Exterior
Wheelbase:
112.1 inches (2847 mm)
Length:
187.4 inches (4760 mm)
Width:
72.4 inches (1839 mm)
Height:
67.2 inches (1707 mm)
Cargo
Cargo Volume Max:
143.7 cubic feet (4069 liters)
Weights
Curb Weight Min:
Approximately 3800 lbs (1724 kg)
Gross Vehicle Weight Rating Gvwr:
Approximately 5600 lbs (2540 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
★★★★☆ (4/5 Stars)
NHTSA Front Impact Passenger:
★★★★☆ (4/5 Stars)
NHTSA Side Impact Front Driver:
★★★★☆ (4/5 Stars)
NHTSA Side Impact Rear Passenger:
★★★★☆ (4/5 Stars)
Active Features
ABS:
Standard on all models
Traction Control:
Optional on some models
Passive Features
Airbags Front:
Driver and Passenger Frontal Airbags
Airbags Side:
Optional Side Curtain Airbags (availability varies by trim)
Seatbelts:
Three-point seat belts for all seating positions
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and/or CD player, optional CD changer.
Display:
Basic digital or analog displays for radio and climate controls.
Driver Assistance
Cruise Control:
Standard on most trims
Rear Parking Sensors:
Optional availability
Connectivity
Auxiliary Input:
Not typically standard, may be aftermarket modification
Bluetooth:
Not available from factory
🔧 Maintenance
Service Intervals
Oil Change Interval Severe:
3,000 miles (4,800 km) or 3 months
Oil Change Interval Normal:
7,500 miles (12,000 km) or 6 months (synthetic oil recommended)
Engine Air Filter Replacement:
15,000-30,000 miles (24,000-48,000 km), or as needed based on inspection
Spark Plug Replacement I4:
100,000 miles (160,000 km) with platinum-tipped plugs
Spark Plug Replacement V6:
100,000 miles (160,000 km) with platinum-tipped plugs
Transmission Fluid Service:
60,000-100,000 miles (96,000-160,000 km) or every 4-5 years
Coolant Flush:
Every 100,000 miles (160,000 km) or 5 years
Fluid Specifications
Engine Oil I4:
SAE 5W-30 (API Service SG or higher, meeting Chrysler MS-6395)
Engine Oil V6:
SAE 5W-30 (API Service SG or higher, meeting Chrysler MS-6395)
Coolant:
Ethylene Glycol Antifreeze (Mopar OAT or HOAT)
Brake Fluid:
DOT 3
Known Issues
Common Problem 1:
Transmission issues (shifting problems, solenoid failures, especially in early models).
Common Problem 2:
Power steering pump leaks or failure.
Common Problem 3:
CV axle wear and boot tears.
Common Problem 4:
Heater core leaks leading to interior steam or coolant smell.
Common Problem 5:
Door lock actuator failures.
📚 Vehicle History
Brand Heritage
Brand:
Dodge (Chrysler Corporation/DaimlerChrysler)
Model Evolution
Generation:
Third Generation (RS/RG Platform)
Design Era:
Rounded, aerodynamic styling
Production
Production Start Year:
1996 (for this generation)
Production End Year:
2007 (for this generation)
Manufacturing Location:
Windsor, Ontario, Canada; Saltillo, Mexico
🏆 Awards & Recognition
Recognitions
Kbb Ratings:
Often cited for practicality and value by Kelley Blue Book in its segment during its production years.
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