Chrysler Caravan 2003-2007 Service Repair Workshop Manual

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Basic Information Identification Make: Chrysler Model: Caravan Codes Vehicle Platform: NS (minivan platform) Introduction Market Position Vehicle Segment: Mid-size Minivan Historical Significance: Part of the highly successful Chrysler minivan lineage, known for practicality and family transport. Competitive Analysis Key Competitors: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Vans (Montana/Venture/Trans Sport). Key Features Distinctive Features: Spacious interior, flexible seating configurations, Stow 'n Go (introduced later in this generation, but core practicality is key), user-friendly design. Manual Value Proposition: Enables owners and technicians to perform accurate diagnostics and repairs, extending vehicle life and maintaining optimal performance. Manual Details Coverage Areas Covered Years: 2003, 2004, 2005, 2006, 2007 Page Count Estimated Pages: Over 2000 pages (typical for full service manuals of this era) Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: 3.3L V6 OHV (EGA), 3.8L V6 OHV (L32), incl. diagnostics, repair, overhaul, timing, cooling, lubrication, fuel, ignition, emissions. Transmission: 41TE/AE (4-Speed Automatic Overdrive), incl. diagnostics, repair, overhaul, fluid service, torque converter, valve body. Brakes: Front disc, rear drum/disc, ABS (Anti-lock Braking System) incl. hydraulic components, parking brake, diagnostic procedures. Suspension: Front independent (MacPherson strut), rear torsion beam with trailing arms, incl. springs, shock absorbers, steering linkage, alignment. Steering: Power-assisted rack and pinion, incl. steering column, linkages, pump, fluid service. Electrical: Battery, charging system (alternator), starting system, lighting, instrumentation, wipers, horns, power accessories, fuses, relays. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, incl. compressor, refrigerant service, heater core, blower motor, climate controls. Body: Body panels, doors, windows, mirrors, interior trim, seat mechanisms, liftgate, sliding doors, glass replacement. Chassis: Frame structure, exhaust system, fuel tank, fuel lines, wheels, tires. Safety Systems: Airbags (SRS), seat belts, child restraint systems (LATCH), pre-tensioners. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection. Diagnostics: Diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting, electrical system diagnostics, engine performance analysis. Repair: Component replacement (e.g., water pump, alternator, starter, brake pads, rotors, sensors), engine and transmission internal repairs, body panel repair. Overhaul: Engine overhaul procedures, transmission rebuild procedures, steering system overhaul. Troubleshooting: Step-by-step troubleshooting guides for common and uncommon issues across all vehicle systems. Wiring Diagrams: Detailed electrical wiring diagrams for all systems, color-coded for clarity. Technical Depth Depth: Comprehensive, covering basic maintenance to complex engine and transmission overhauls, including detailed diagnostic procedures and specifications. Target Audience: Professional mechanics, DIY enthusiasts, service technicians. Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Searchable Text: Yes (typically OCR'd for searchability) Resolution: High resolution for clear diagrams and text. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Engine Specifications Primary Engine Engine Code 1: EGA Engine Description 1: 3.3L (3301 cc) OHV V6, 12-valve Bore Stroke 1: 93.0 mm x 81.0 mm Compression Ratio 1: 9.1:1 Horsepower 1: Approx. 175 hp @ 5000 rpm (varies slightly by year) Torque 1: Approx. 205 lb-ft @ 4000 rpm (varies slightly by year) Optional Engine Engine Code 2: L32 Engine Description 2: 3.8L (3778 cc) OHV V6, 12-valve Bore Stroke 2: 94.5 mm x 90.9 mm Compression Ratio 2: 8.9:1 Horsepower 2: Approx. 205 hp @ 5000 rpm (varies slightly by year) Torque 2: Approx. 235 lb-ft @ 3200 rpm (varies slightly by year) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane (minimum) Cooling System Cooling Type: Pressurized liquid cooling system Lubrication System Oil Capacity: Approx. 4.5 quarts (4.3 L) with filter (3.3L V6), Approx. 5.0 quarts (4.7 L) with filter (3.8L V6) - consult manual for exact capacity and oil type. Ignition System Ignition Type: Distributorless Ignition System (DIS) with ignition coils. Transmission Standard Transmission Type Standard: 4-Speed Automatic Overdrive (41TE/AE) Optional Transmission Type Optional: N/A (41TE/AE was standard for most configurations) Features Transmission Fluid: ATF+4 (Automatic Transmission Fluid Type 9602) Transmission Fluid Capacity: Approx. 3.0 quarts (2.8 L) for dry fill, 6.5 quarts (6.2 L) total capacity (consult manual for precise figures and procedures). Torque Converter: Lock-up torque converter Dimensions Exterior Length: Approx. 190.0 inches (4826 mm) Width: Approx. 72.0 inches (1829 mm) Height: Approx. 67.0 inches (1702 mm) Wheelbase: Approx. 113.0 inches (2870 mm) Cargo Cargo Volume Behind 3Rd Row: Approx. 30.5 cubic feet (864 L) Cargo Volume Behind 2Nd Row: Approx. 85.0 cubic feet (2407 L) (with 3rd row removed/folded) Cargo Volume Max: Approx. 150.0 cubic feet (4248 L) (with 2nd and 3rd rows removed/folded) Weights Curb Weight: Approx. 3800 - 4200 lbs (1724 - 1905 kg) depending on configuration Gross Vehicle Weight Rating: Approx. 5400 - 5800 lbs (2449 - 2631 kg) Safety Features Ratings NHTSA Frontal Crash Test Driver: 4-star (for models tested) NHTSA Frontal Crash Test Passenger: 4-star (for models tested) IIHS Side Impact: Good (for models equipped with side...

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Tipo: Car

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Sku: 74765

Coleções: ALL Chrysler Marine

Disponibilidade: Em estoque

Tag: 2003 2004 2005 2006 2007 Car Caravan Chrysler Marine Misc Outboard Engines

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Description

Basic Information
Identification
Make:	Chrysler
Model:	Caravan
Codes
Vehicle Platform:	NS (minivan platform)

Introduction
Market Position
Vehicle Segment:	Mid-size Minivan
Historical Significance:	Part of the highly successful Chrysler minivan lineage, known for practicality and family transport.
Competitive Analysis
Key Competitors:	Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Vans (Montana/Venture/Trans Sport).
Key Features
Distinctive Features:	Spacious interior, flexible seating configurations, Stow 'n Go (introduced later in this generation, but core practicality is key), user-friendly design.
Manual Value Proposition:	Enables owners and technicians to perform accurate diagnostics and repairs, extending vehicle life and maintaining optimal performance.

Manual Details
Coverage Areas
Covered Years:	2003, 2004, 2005, 2006, 2007
Page Count
Estimated Pages:	Over 2000 pages (typical for full service manuals of this era)
Manual Type
Manual Type:	Service and Repair Workshop Manual
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine:	3.3L V6 OHV (EGA), 3.8L V6 OHV (L32), incl. diagnostics, repair, overhaul, timing, cooling, lubrication, fuel, ignition, emissions.
Transmission:	41TE/AE (4-Speed Automatic Overdrive), incl. diagnostics, repair, overhaul, fluid service, torque converter, valve body.
Brakes:	Front disc, rear drum/disc, ABS (Anti-lock Braking System) incl. hydraulic components, parking brake, diagnostic procedures.
Suspension:	Front independent (MacPherson strut), rear torsion beam with trailing arms, incl. springs, shock absorbers, steering linkage, alignment.
Steering:	Power-assisted rack and pinion, incl. steering column, linkages, pump, fluid service.
Electrical:	Battery, charging system (alternator), starting system, lighting, instrumentation, wipers, horns, power accessories, fuses, relays.
HVAC:	Heating, Ventilation, and Air Conditioning (HVAC) system, incl. compressor, refrigerant service, heater core, blower motor, climate controls.
Body:	Body panels, doors, windows, mirrors, interior trim, seat mechanisms, liftgate, sliding doors, glass replacement.
Chassis:	Frame structure, exhaust system, fuel tank, fuel lines, wheels, tires.
Safety Systems:	Airbags (SRS), seat belts, child restraint systems (LATCH), pre-tensioners.
Procedures Included
Maintenance:	Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection.
Diagnostics:	Diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting, electrical system diagnostics, engine performance analysis.
Repair:	Component replacement (e.g., water pump, alternator, starter, brake pads, rotors, sensors), engine and transmission internal repairs, body panel repair.
Overhaul:	Engine overhaul procedures, transmission rebuild procedures, steering system overhaul.
Troubleshooting:	Step-by-step troubleshooting guides for common and uncommon issues across all vehicle systems.
Wiring Diagrams:	Detailed electrical wiring diagrams for all systems, color-coded for clarity.
Technical Depth
Depth:	Comprehensive, covering basic maintenance to complex engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Target Audience:	Professional mechanics, DIY enthusiasts, service technicians.

Manual Specifications
File Format
File Format:	PDF (Portable Document Format)
Print Quality
Searchable Text:	Yes (typically OCR'd for searchability)
Resolution:	High resolution for clear diagrams and text.
Binding Type
Binding Type:	Not Applicable (Digital Download)
Paper Type
Paper Type:	Not Applicable (Digital Download)

Engine Specifications
Primary Engine
Engine Code 1:	EGA
Engine Description 1:	3.3L (3301 cc) OHV V6, 12-valve
Bore Stroke 1:	93.0 mm x 81.0 mm
Compression Ratio 1:	9.1:1
Horsepower 1:	Approx. 175 hp @ 5000 rpm (varies slightly by year)
Torque 1:	Approx. 205 lb-ft @ 4000 rpm (varies slightly by year)
Optional Engine
Engine Code 2:	L32
Engine Description 2:	3.8L (3778 cc) OHV V6, 12-valve
Bore Stroke 2:	94.5 mm x 90.9 mm
Compression Ratio 2:	8.9:1
Horsepower 2:	Approx. 205 hp @ 5000 rpm (varies slightly by year)
Torque 2:	Approx. 235 lb-ft @ 3200 rpm (varies slightly by year)
Fuel System
Fuel Delivery:	Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:	Unleaded gasoline, 87 octane (minimum)
Cooling System
Cooling Type:	Pressurized liquid cooling system
Lubrication System
Oil Capacity:	Approx. 4.5 quarts (4.3 L) with filter (3.3L V6), Approx. 5.0 quarts (4.7 L) with filter (3.8L V6) - consult manual for exact capacity and oil type.
Ignition System
Ignition Type:	Distributorless Ignition System (DIS) with ignition coils.

Transmission
Standard
Transmission Type Standard:	4-Speed Automatic Overdrive (41TE/AE)
Optional
Transmission Type Optional:	N/A (41TE/AE was standard for most configurations)
Features
Transmission Fluid:	ATF+4 (Automatic Transmission Fluid Type 9602)
Transmission Fluid Capacity:	Approx. 3.0 quarts (2.8 L) for dry fill, 6.5 quarts (6.2 L) total capacity (consult manual for precise figures and procedures).
Torque Converter:	Lock-up torque converter

Dimensions
Exterior
Length:	Approx. 190.0 inches (4826 mm)
Width:	Approx. 72.0 inches (1829 mm)
Height:	Approx. 67.0 inches (1702 mm)
Wheelbase:	Approx. 113.0 inches (2870 mm)
Cargo
Cargo Volume Behind 3Rd Row:	Approx. 30.5 cubic feet (864 L)
Cargo Volume Behind 2Nd Row:	Approx. 85.0 cubic feet (2407 L) (with 3rd row removed/folded)
Cargo Volume Max:	Approx. 150.0 cubic feet (4248 L) (with 2nd and 3rd rows removed/folded)
Weights
Curb Weight:	Approx. 3800 - 4200 lbs (1724 - 1905 kg) depending on configuration
Gross Vehicle Weight Rating:	Approx. 5400 - 5800 lbs (2449 - 2631 kg)

Safety Features
Ratings
NHTSA Frontal Crash Test Driver:	4-star (for models tested)
NHTSA Frontal Crash Test Passenger:	4-star (for models tested)
IIHS Side Impact:	Good (for models equipped with side airbags)
Active Features
ABS:	Standard Anti-lock Braking System (ABS) on most trims.
Traction Control:	Optional on some models/trims.
Passive Features
Airbags Standard:	Driver and front passenger airbags.
Airbags Optional:	Available side curtain airbags for first and second rows (late in generation).
Seat Belts:	Three-point seat belts for all outboard seating positions, center lap belt for rear middle seat, pretensioners for front seats.
Child Safety Anchors:	LATCH (Lower Anchors and Tethers for Children) system.

Technology Features
Infotainment
Audio System:	Factory AM/FM stereo with CD player, optional cassette player, and premium speaker systems available on higher trims.
Rear Seat Entertainment:	Optional factory-installed rear-seat entertainment system with video screen and wireless headphones.
Driver Assistance
Cruise Control:	Standard electronic cruise control.
Parking Sensors:	Optional rear park assist sensors available on some models.
Connectivity
Remote Keyless Entry:	Available remote keyless entry system.
Power Windows Locks Mirrors:	Available power windows, power door locks, and power adjustable mirrors.

Maintenance
Service Intervals
Oil Change Interval:	Every 3,000-7,500 miles (4,800-12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).
Air Filter Replacement:	Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:	Approx. 100,000 miles (160,000 km) for platinum or iridium plugs.
Transmission Fluid Change:	Every 30,000-60,000 miles (48,000-96,000 km) or as recommended by the manual, especially for severe service.
Fluid Specifications
Engine Oil Type:	SAE 5W-30 Synthetic Blend or Full Synthetic is generally recommended (verify with manual for specific viscosity and API rating).
Coolant Type:	Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, HOAT (Hybrid Organic Additive Technology) or equivalent extended-life coolant. Typically orange or pink.
Brake Fluid Type:	DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Mounts:	Premature wear or failure of engine and transmission mounts can lead to vibrations and noise.
Transmission Solenoids:	Internal transmission solenoid issues can cause shifting problems or a 'limp home' mode.
Power Sliding Doors:	Malfunctions in the power sliding door motors, mechanisms, or sensors are common.
Interior Rattles And Squeaks:	Common in high-mileage minivans, often related to interior trim panels and seating mechanisms.
Rear Suspension Noise:	Worn bushings or shocks in the rear suspension can cause clunking or rattling noises.
Climate Control Blend Doors:	Actuator failure for interior air blend doors can result in incorrect temperature or air direction.

Vehicle History
Brand Heritage
Chrysler Minivan Legacy:	Chrysler invented the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983, setting the standard for family vehicles.
Model Evolution
Generation:	Third Generation (NS) platform
Year Range Covered:	2003-2007 (facelift of the NS platform).
Key Updates 2003-2007:	Front and rear styling updates, revised interior materials, introduction of optional power sliding doors and liftgate, improved powertrain options, introduction of Stow 'n Go seating in later years of this generation (though primarily for the next generation, the foundation was set).
Production
Manufacturing Location:	Windsor, Ontario, Canada; St. Louis, Missouri, USA.
Market Introduction:	The Caravan nameplate has been a staple in Chrysler's lineup since its inception.