DODGE CARAVAN 2003-2007 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year Range: 2003-2007 Codes Platform Code: NS (3rd Generation - Chrysler minivans) 👋 Introduction Market Position Segment: Minivan Target Audience: DIY mechanics, independent repair shops, fleet maintenance Competitive Analysis Competitors: Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Venture/Montana Key Features Manual Advantage: Provides factory-level detail for a wide range of repairs and maintenance, crucial for a vehicle as complex as a minivan. Vehicle Utility: Designed for family transport, cargo hauling, and towing (within limits), requiring thorough maintenance for reliability. 📋 Manual Details Coverage Areas Coverage Type: Full Service and Repair Page Count Estimated Page Count: 1500-2000+ (typical for comprehensive factory-level manuals) Manual Type Manual Type: Service Manual / Repair Manual Language Language: English Format Format: Digital (likely PDF, potentially with search functionality) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system Transmission: Automatic transmission (e.g., 41TE, 42LE) service, diagnostics, and repair Drivetrain: Front-wheel drive axle and suspension components Brakes: Hydraulic brake system, ABS (Anti-lock Braking System), parking brake Steering: Power steering system, steering column, steering gear Suspension: Front and rear suspension systems, shock absorbers, struts, control arms, bushings Electrical: Battery, charging system, starting system, lighting, instruments, power accessories, trailer wiring Body: Body structure, interior trim, exterior trim, doors, windows, seats, sunroof (if applicable) HVAC: Heating, Ventilation, and Air Conditioning system service and repair Restraint Systems: Airbag system (SRS), seat belts Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), diagnostic procedures Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, tune-ups Troubleshooting: Diagnostic flowcharts, common problems and solutions, symptom-based troubleshooting Repair: Component removal, installation, overhaul, and adjustment procedures Adjustment: Alignment specifications, brake adjustments, clutch adjustments (if manual transmission was an option, which is unlikely for this model) Wiring Diagrams: Complete electrical wiring schematics for all systems Specifications: Torque specifications, tolerances, fluid capacities, electrical specifications Technical Depth Depth Level: Comprehensive (includes basic maintenance to complex component overhauls and diagnostics) Diagnostic Capability: Advanced (details on using diagnostic tools, interpreting sensor data, and specific diagnostic procedures for various faults) Rebuild Procedures: Detailed procedures for engine and transmission rebuilding (if applicable to the depth of the manual) 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Resolution: High resolution, suitable for clear printing of diagrams and text Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Searchability Text Search: Likely searchable text for quick information retrieval Navigation Internal Linking: May include internal hyperlinks for easier navigation between sections and diagrams ⚙️ Engine Specifications Primary Engine Engine Code: EDZ (3.3L V6) Engine Type: 3.3L OHV V6 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: 9.0:1 Horsepower: Approx. 180-185 hp @ 5000-5200 rpm Torque: Approx. 200-210 lb-ft @ 3200-3400 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane recommended Engine Oil Oil Type Specification: API Certified SAE 5W-30 Oil Capacity: Approx. 4.5 quarts (4.3 liters) with filter change Ignition System Ignition Type: Distributorless Ignition System (DIS) with coil-on-plug (COP) or coil pack 🔧 Transmission Standard Transmission Transmission Type: 4-Speed Automatic Transaxle Transmission Model Codes: 41TE, 42LE Fluid Type: ATF+4 (Mopar P/N 05013457AA or equivalent) Fluid Capacity: Approx. 4.5 quarts (4.3 liters) dry fill; 3.5 quarts (3.3 liters) for fluid change Features Overdrive: Yes (4th gear) Torque Converter: Lock-up torque converter 📐 Dimensions Exterior Wheelbase: Approx. 119.3 inches (3030 mm) Length: Approx. 189.8 inches (4820 mm) Width: Approx. 76.5 inches (1943 mm) Height: Approx. 68.0 inches (1727 mm) Weights Curb Weight: Approx. 4000-4400 lbs (1814-2000 kg), varies by trim and equipment Cargo Max Cargo Volume Behind 1St Row: Approx. 140-150 cu. ft. (with removable seats) Max Cargo Volume Behind 2Nd Row: Approx. 80-90 cu. ft. (with removable seats) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (for 2003 models, varying slightly by year) NHTSA Front Impact Passenger: 4 Stars (for 2003 models, varying slightly by year) NHTSA Side Impact Front Driver: 5 Stars (for 2003 models, varying slightly by year) NHTSA Side Impact Front Passenger: 5 Stars (for 2003 models, varying slightly by year) NHTSA Side Impact Rear Passenger: 4 Stars (for 2003 models, varying slightly by year) Active Features ABS: Standard Anti-lock Braking System (ABS) Passive Features Airbags: Driver and front passenger airbags, optional side airbags Seatbelts: 3-point active seatbelts with pretensioners and load limiters 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette, and rear entertainment system (VES - Video Entertainment System). Driver Assistance Cruise Control: Standard on most trims. Parking Assist: Optional rear parking assist sensors. Connectivity Trailer Wiring: Provision for trailer towing wiring harness, with specifications for connection. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000...
Approx. 4000-4400 lbs (1814-2000 kg), varies by trim and equipment
Cargo
Max Cargo Volume Behind 1St Row:
Approx. 140-150 cu. ft. (with removable seats)
Max Cargo Volume Behind 2Nd Row:
Approx. 80-90 cu. ft. (with removable seats)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (for 2003 models, varying slightly by year)
NHTSA Front Impact Passenger:
4 Stars (for 2003 models, varying slightly by year)
NHTSA Side Impact Front Driver:
5 Stars (for 2003 models, varying slightly by year)
NHTSA Side Impact Front Passenger:
5 Stars (for 2003 models, varying slightly by year)
NHTSA Side Impact Rear Passenger:
4 Stars (for 2003 models, varying slightly by year)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point active seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette, and rear entertainment system (VES - Video Entertainment System).
Driver Assistance
Cruise Control:
Standard on most trims.
Parking Assist:
Optional rear parking assist sensors.
Connectivity
Trailer Wiring:
Provision for trailer towing wiring harness, with specifications for connection.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, or as indicated by the oil change indicator system.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Platinum-tipped spark plugs generally last 60,000-100,000 miles (96,000-160,000 km). Refer to manual for specific type and interval.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km) or as recommended by the manual, especially if used for towing.
Fluid Specifications
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically pink or orange. Mopar Antifreeze/Coolant (MS-9769) recommended.
Coolant Capacity:
Approx. 11.5 quarts (10.9 liters)
Brake Fluid Type:
DOT 3
Power Steering Fluid:
Mopar Power Steering Fluid (MS-5901) or equivalent
Known Issues
Transmission Hard Shifting:
Common concern with the 41TE/42LE transmissions, often related to solenoid packs or valve body issues. Manual will detail diagnostic steps.
Engine Oil Leaks:
Can occur from valve cover gaskets, oil pan gaskets, or crankshaft seals. Manual covers replacement procedures.
Power Door Locks And Windows:
Electrical gremlins can affect these systems; manual provides wiring diagrams and troubleshooting for motors, switches, and control modules.
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear out due to vehicle weight and mileage. Manual specifies inspection and replacement.
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler Corporation's entry into the minivan market, revolutionizing family transportation.
Model Evolution
Generation:
This generation (NS) represents the third major redesign of the Dodge Caravan/Chrysler Town & Country platform.
Design Changes:
Features a smoother, more aerodynamic design compared to the previous generation, with improved interior packaging and available features.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Period:
2000-2007 (for the NS platform, with facelifts/updates during this time)
🏆 Awards & Recognition
Recognitions
Initial Reception:
The NS platform was generally well-received for its improved styling, interior space, and comfort when introduced.
Ratings
Consumer Reports Reliability:
Varied by year and specific components, but often rated average to below average for reliability in its later years of production. The manual is essential for addressing potential issues.
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