Dodge Caravan 2003-2007 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Product Name: Dodge Caravan 2003-2007 Workshop Service Repair Manual Applicable Years: 2003, 2004, 2005, 2006, 2007 Codes Generation Code: Fourth Generation (RS) 👋 Introduction Market Position Market Segment: Minivan segment, known for practicality, family transport, and versatility. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Buick Terraza. Key Features Vehicle Versatility: Flexible seating configurations (Stow 'n Go became prominent in later generations, but the 2003-2007 models offered good interior space and modularity). Engine Options: Known for offering reliable V6 engine options. Key Features Manual Value Proposition: Essential resource for DIY mechanics and professional repair shops to maintain and repair the Dodge Caravan efficiently. 📋 Manual Details Coverage Areas Manual Coverage Scope: Complete factory service and repair procedures for all systems of the Dodge Caravan. Page Count Estimated Page Count: Hundreds of pages (specific number not provided, implies a comprehensive volume) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (likely PDF) File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: Not applicable (digital download) Paper Type Paper Type: Not applicable (digital download) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission controls, engine control module (ECM) diagnostics. Transmission Systems: Automatic transmission (e.g., 41TE, 42LE) service, repair, overhaul, diagnostics, and fluid specifications. Drivetrain Systems: Front-wheel drive (FWD) systems, including axle shafts, differentials, and related components. Suspension Steering: Front and rear suspension components, steering system, power steering, alignment specifications. Brake Systems: Front and rear brakes (disc/drum configurations), ABS system diagnostics and repair, hydraulic components. Electrical Systems: Wiring diagrams, charging system, starting system, lighting, instrument cluster, power windows, door locks, body control module (BCM). HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant handling, component testing. Body Interior: Body panel repair, doors, windows, interior trim, seating, airbags, seat belts. Diagnostic Troubleshooting: Trouble codes (DTCs), diagnostic procedures, symptom-based troubleshooting charts. Procedures Included Maintenance Procedures: Routine maintenance tasks such as oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection/replacement. Repair Procedures: Detailed step-by-step repair instructions for all major vehicle components and systems. Overhaul Procedures: Engine and transmission overhaul procedures, including component specifications and tolerances. Installation Procedures: Instructions for installing replacement parts and accessories. Torque Specifications: Crucial torque values for all fasteners to ensure proper assembly and prevent damage. Diagnostic Procedures: Systematic diagnostic routines to identify the root cause of malfunctions. Technical Depth Technical Depth Level: Comprehensive, covering basic to advanced repairs and diagnostics. Diagnostic Tool Requirements: Information on required diagnostic tools, including OBD-II scanners and specialized testers. ⚙️ Engine Specifications Primary Engine Engine 2 4L I4: 2.4L DOHC Inline-4 (Optional in some markets/trims, often base engine). Engine 3 3L V6: 3.3L OHV V6 (Commonly available, known for torque and reliability). Engine 3 8L V6: 3.8L OHV V6 (Optional, offered more power). Performance 3 3L V6 Horsepower: Approx. 180-185 hp (depending on year and specific calibration). 3 3L V6 Torque: Approx. 210-215 lb-ft (depending on year and specific calibration). 3 8L V6 Horsepower: Approx. 200-205 hp (depending on year and specific calibration). 3 8L V6 Torque: Approx. 230-235 lb-ft (depending on year and specific calibration). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Multi-port Fuel Injection (MPI). Fuel Type: Unleaded gasoline (87 octane recommended for most engines). 🔧 Transmission Standard Transmission Type Standard: 4-speed Automatic Transmission (e.g., 41TE/42LE family). Optional Transmission Type Optional: Not typically offered with manual transmissions in this generation. Features Transmission Control: Electronically controlled automatic transmission with torque converter lock-up. 📐 Dimensions Exterior Wheelbase: Approx. 119.3 inches (Standard wheelbase). Length: Approx. 189.4 - 193.8 inches (depending on specific model/configuration). Cargo Cargo Volume Behind 3Rd Row: Varies by configuration, but typically around 20-30 cubic feet. Cargo Volume Max: Can exceed 100 cubic feet with rear seats removed or folded. Weights Curb Weight: Approx. 3800 - 4200 lbs (depending on engine and trim). 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating Driver: Generally good for its era (e.g., 4 or 5 stars in some frontal impact tests, but consult specific year reports). NHTSA Frontal Crash Rating Passenger: Generally good for its era (e.g., 4 or 5 stars in some frontal impact tests, but consult specific year reports). Active Features ABS: Standard Anti-lock Braking System (ABS) on most models/trims. Traction Control: Optional Traction Control System (TCS) on some models. Passive Features Airbags Front: Standard front driver and passenger airbags. Airbags Side: Optional side-impact airbags or side curtain airbags available on some later models/trims within this range. Seat Belts: Three-point seat belts for all outboard seating positions, integrated child seat anchors (LATCH). 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio systems, rear-seat entertainment systems available on...
Dodge Caravan 2003-2007 Workshop Service Repair Manual
Applicable Years:
2003, 2004, 2005, 2006, 2007
Codes
Generation Code:
Fourth Generation (RS)
👋 Introduction
Market Position
Market Segment:
Minivan segment, known for practicality, family transport, and versatility.
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Buick Terraza.
Key Features Vehicle
Versatility:
Flexible seating configurations (Stow 'n Go became prominent in later generations, but the 2003-2007 models offered good interior space and modularity).
Engine Options:
Known for offering reliable V6 engine options.
Key Features Manual
Value Proposition:
Essential resource for DIY mechanics and professional repair shops to maintain and repair the Dodge Caravan efficiently.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Complete factory service and repair procedures for all systems of the Dodge Caravan.
Page Count
Estimated Page Count:
Hundreds of pages (specific number not provided, implies a comprehensive volume)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (likely PDF)
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Not typically offered with manual transmissions in this generation.
Features
Transmission Control:
Electronically controlled automatic transmission with torque converter lock-up.
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.3 inches (Standard wheelbase).
Length:
Approx. 189.4 - 193.8 inches (depending on specific model/configuration).
Cargo
Cargo Volume Behind 3Rd Row:
Varies by configuration, but typically around 20-30 cubic feet.
Cargo Volume Max:
Can exceed 100 cubic feet with rear seats removed or folded.
Weights
Curb Weight:
Approx. 3800 - 4200 lbs (depending on engine and trim).
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating Driver:
Generally good for its era (e.g., 4 or 5 stars in some frontal impact tests, but consult specific year reports).
NHTSA Frontal Crash Rating Passenger:
Generally good for its era (e.g., 4 or 5 stars in some frontal impact tests, but consult specific year reports).
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models/trims.
Traction Control:
Optional Traction Control System (TCS) on some models.
Passive Features
Airbags Front:
Standard front driver and passenger airbags.
Airbags Side:
Optional side-impact airbags or side curtain airbags available on some later models/trims within this range.
Seat Belts:
Three-point seat belts for all outboard seating positions, integrated child seat anchors (LATCH).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems, rear-seat entertainment systems available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
OBD Ii Port:
On-Board Diagnostics II (OBD-II) port for engine and emissions system diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions (refer to manual for specific recommendations).
Transmission Fluid Change:
Recommended every 30,000-100,000 miles, depending on usage and fluid type (crucial for automatic transmission longevity).
Spark Plug Replacement:
Typically around 60,000-100,000 miles for platinum or iridium spark plugs.
Fluid Specifications
Engine Oil Specification:
Refer to manual, typically SAE 5W-30 or 10W-30 for V6 engines (check specific engine for correct viscosity and API rating).
Transmission Fluid Specification:
ATF+4 (Automatic Transmission Fluid type 4) is standard for Chrysler/Dodge automatics of this era.
Coolant Specification:
Chrysler/Dodge Antifreeze/Coolant (HOAT formula, typically pink or orange).
Known Issues
Transmission Issues:
Some models of this generation have experienced issues with solenoid packs, valve body problems, and premature wear in automatic transmissions if not properly maintained.
Engine Mounts:
Engine mounts can wear over time, leading to increased vibration and noise.
Power Sliding Doors:
Power sliding door mechanisms can sometimes develop issues with motors, cables, or sensors.
Cv Axles:
Front Constant Velocity (CV) axles can wear, leading to clicking noises during turns.
Brake Wear:
Like many minivans, brake wear can be a regular maintenance item, especially under heavy use.
📚 Vehicle History
Brand Heritage
Dodge Minivan Legacy:
Dodge pioneered the minivan segment with the original Caravan/Voyager in the 1980s, establishing its reputation for family-friendly vehicles.
Model Evolution
Fourth Generation Rs Introduction:
The RS generation, introduced for the 2001 model year, featured a significant redesign with improved aerodynamics, interior space, and updated powertrains.
Facelift Updates:
The 2003-2007 models represent updates and refinements within the fourth generation, including potential styling tweaks and feature enhancements.
Production
Assembly Locations:
Primarily assembled in Windsor, Ontario, Canada, and Saltillo, Mexico.
🏆 Awards & Recognition
Recognitions
Minivan Segment Popularity:
The Dodge Caravan consistently ranked as a popular choice in the minivan segment for its practicality and value, earning it a strong market presence.
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