Chrysler Caravan 2003-2007 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Codes Platform: NS/RS 👋 Introduction Market Position Segment: Mid-size Minivan Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture Key Features Vehicle Identity: The Chrysler Caravan was a benchmark for the minivan segment, known for its versatility, family-friendly features, and comfortable ride. Manual Purpose: Essential for DIY enthusiasts, professional mechanics, and fleet managers seeking to maintain or repair their 2003-2007 Chrysler Caravan. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Years Covered: 2003, 2004, 2005, 2006, 2007 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, cooling system, lubrication system, fuel system (including MPI), ignition system, exhaust system, emissions control Drivetrain: Automatic transmission (41TE/42LE), transaxle, clutch (if applicable), drive axles, differentials Chassis Systems: Suspension (front and rear), steering system, braking system (including ABS), wheel alignment Electrical Systems: Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), wiring diagrams, diagnostic trouble codes (DTCs) Body Systems: Body construction, doors, windows, seats, interior trim, HVAC (Heating, Ventilation, and Air Conditioning), exterior body panels, collision repair basics Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, tire rotation, tune-ups Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble code (DTC) interpretation and resolution, electrical circuit testing, mechanical component testing Repair: Step-by-step repair procedures for major components, engine disassembly/reassembly, transmission repair, brake caliper replacement, suspension component replacement, electrical module repair Installation: Component replacement procedures, timing belt/chain replacement, accessory installation (e.g., alternator, starter), brake pad and rotor replacement Technical Depth Depth: Comprehensive coverage from basic maintenance to in-depth engine, transmission, and electrical diagnostics and repair. Includes detailed specifications and torque values. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable PDF for quick access to information Print Quality Printability: Printable pages for easy reference while working Binding Type Digital Format: Downloadable file, no physical binding Paper Type Digital Medium: Digital delivery ⚙️ Engine Specifications Primary Engine Engine Code And Type: EDZ 3.3L V6 SOHC (OHV in earlier variants, SOHC for this generation) Displacement: 3.3 Liters (201 cubic inches) Bore X Stroke: 3.77 x 3.58 inches (96mm x 91mm) Compression Ratio: 9.4:1 Horsepower Est: 180 hp @ 5000 rpm Torque Est: 205 lb-ft @ 4000 rpm Optional Engine Engine Code And Type: EGA 3.8L V6 OHV Displacement: 3.8 Liters (230 cubic inches) Horsepower Est: 200-215 hp @ 5000-5200 rpm (depending on year/tune) Torque Est: 230-245 lb-ft @ 4000-4400 rpm (depending on year/tune) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane recommended Performance 0 60 Mph Est: 9.0 - 10.5 seconds (depending on engine and load) 🔧 Transmission Standard Type: 4-Speed Automatic Transaxle (e.g., 41TE/42LE series) Optional Type: Not typically offered, but some Heavy Duty models might have variations. Features Electronic Control: Electronically controlled with a focus on driver comfort and fuel economy. Fluid Specifications Fluid Type: Chrysler ATF+4 (Automatic Transmission Fluid type 9602) Fluid Capacity Capacity Quarts: Approx. 4.0 quarts (dry fill), 8.5-9.5 quarts (total capacity) 📐 Dimensions Exterior Length: Approx. 189.4 inches (standard wheelbase), 201.1 inches (long wheelbase) Width: Approx. 72.0 inches Height: Approx. 66.0 - 68.7 inches (depending on roof rack) Interior Passenger Volume Cu Ft: Approx. 145-165 cu ft (depending on configuration) Cargo Cargo Volume Cu Ft Rear Seats Folded: Approx. 140-150 cu ft Cargo Volume Cu Ft Behind 3Rd Row: Approx. 25-35 cu ft Weights Curb Weight Lbs Est: 3700 - 4300 lbs (depending on engine and options) Gross Vehicle Weight Rating Gvwr Lbs Est: 5300 - 5700 lbs Towing Capacity Lbs Est: Up to 3,800 lbs (with optional towing package) 🛡️ Safety Features Ratings NHTSA Front Driver Side Impact: 5 Stars (for most models in this range) NHTSA Front Passenger Side Impact: 5 Stars (for most models in this range) IIHS Frontal Offset Rating: Good (for many models in this range) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) on some models Passive Features Airbags: Front airbags for driver and front passenger; optional side curtain airbags available on later models Seatbelts: 3-point seat belts with pretensioners for front occupants, LATCH child seat anchor system 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional cassette, premium Infinity sound systems available. Rear Seat Entertainment: Optional rear-seat video screens and DVD players available on higher trims. Driver Assistance Cruise Control: Standard cruise control. Connectivity Power Accessories: Power windows, power locks, power mirrors, power sliding doors and liftgate available on many models. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months, whichever comes first (using synthetic blend or full synthetic oil). Air Filter Replacement Interval: Every 30,000 miles or as needed based on inspection. Cabin Air Filter Replacement Interval: Every 15,000 - 30,000 miles or...
Suspension (front and rear), steering system, braking system (including ABS), wheel alignment
Electrical Systems:
Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), wiring diagrams, diagnostic trouble codes (DTCs)
Body Systems:
Body construction, doors, windows, seats, interior trim, HVAC (Heating, Ventilation, and Air Conditioning), exterior body panels, collision repair basics
Troubleshooting guides for common symptoms, diagnostic trouble code (DTC) interpretation and resolution, electrical circuit testing, mechanical component testing
Repair:
Step-by-step repair procedures for major components, engine disassembly/reassembly, transmission repair, brake caliper replacement, suspension component replacement, electrical module repair
Installation:
Component replacement procedures, timing belt/chain replacement, accessory installation (e.g., alternator, starter), brake pad and rotor replacement
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to in-depth engine, transmission, and electrical diagnostics and repair. Includes detailed specifications and torque values.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable PDF for quick access to information
Print Quality
Printability:
Printable pages for easy reference while working
Binding Type
Digital Format:
Downloadable file, no physical binding
Paper Type
Digital Medium:
Digital delivery
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EDZ 3.3L V6 SOHC (OHV in earlier variants, SOHC for this generation)
Displacement:
3.3 Liters (201 cubic inches)
Bore X Stroke:
3.77 x 3.58 inches (96mm x 91mm)
Compression Ratio:
9.4:1
Horsepower Est:
180 hp @ 5000 rpm
Torque Est:
205 lb-ft @ 4000 rpm
Optional Engine
Engine Code And Type:
EGA 3.8L V6 OHV
Displacement:
3.8 Liters (230 cubic inches)
Horsepower Est:
200-215 hp @ 5000-5200 rpm (depending on year/tune)
Torque Est:
230-245 lb-ft @ 4000-4400 rpm (depending on year/tune)
Approx. 66.0 - 68.7 inches (depending on roof rack)
Interior
Passenger Volume Cu Ft:
Approx. 145-165 cu ft (depending on configuration)
Cargo
Cargo Volume Cu Ft Rear Seats Folded:
Approx. 140-150 cu ft
Cargo Volume Cu Ft Behind 3Rd Row:
Approx. 25-35 cu ft
Weights
Curb Weight Lbs Est:
3700 - 4300 lbs (depending on engine and options)
Gross Vehicle Weight Rating Gvwr Lbs Est:
5300 - 5700 lbs
Towing Capacity Lbs Est:
Up to 3,800 lbs (with optional towing package)
🛡️ Safety Features
Ratings
NHTSA Front Driver Side Impact:
5 Stars (for most models in this range)
NHTSA Front Passenger Side Impact:
5 Stars (for most models in this range)
IIHS Frontal Offset Rating:
Good (for many models in this range)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) on some models
Passive Features
Airbags:
Front airbags for driver and front passenger; optional side curtain airbags available on later models
Seatbelts:
3-point seat belts with pretensioners for front occupants, LATCH child seat anchor system
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional cassette, premium Infinity sound systems available.
Rear Seat Entertainment:
Optional rear-seat video screens and DVD players available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Power Accessories:
Power windows, power locks, power mirrors, power sliding doors and liftgate available on many models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (using synthetic blend or full synthetic oil).
Air Filter Replacement Interval:
Every 30,000 miles or as needed based on inspection.
Cabin Air Filter Replacement Interval:
Every 15,000 - 30,000 miles or annually, depending on environment.
Spark Plug Replacement Interval:
Platinum-tipped plugs: 100,000 miles. Standard plugs (if used): 30,000 miles.
Transmission Fluid Change Interval:
Every 60,000 - 100,000 miles, or sooner under severe driving conditions. Consult manual for specific severe service intervals.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30, meeting Chrysler MS-6395 specification.
Coolant Spec:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, color may vary (typically orange/pink). Mopar OAT is also acceptable if compatible.
Power Steering Fluid Spec:
Chrysler MS-5901 or equivalent ATF+4 (check specific year/model).
Brake Fluid Spec:
DOT 3 or DOT 4.
Known Issues
Engine Idle Roughness:
Can be caused by intake manifold gasket leaks, vacuum leaks, or faulty EGR valve.
Transmission Slipping Harsh Shifts:
Often related to low fluid level, worn clutch packs, or faulty solenoids. Torque converter issues can also occur.
Power Door Lock Failure:
Actuators and control modules are common failure points.
Rear Wiper Failure:
Motor failure or wiring issues.
HVAC Blower Motor Failure:
Blower motor and resistor failure are common.
📚 Vehicle History
Brand Heritage
Chrysler Legacy:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager (which shared platforms with the Chrysler Caravan) in the mid-1980s.
Model Evolution
Third Generation:
This 2003-2007 period represents the latter half of the third generation (NS/RS platform) of the Dodge Caravan/Grand Caravan and Chrysler Voyager/Town & Country, with the Chrysler Caravan being a specific trim or variant within this lineup.
Production
Manufacturing Locations:
Primarily Windsor, Ontario, Canada and St. Louis, Missouri, USA.
Model Timeline:
Introduced as part of the third generation in 1996, with significant updates for 2001. The 2003-2007 period received minor refreshes and feature packaging updates.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
While not always winning, minivans of this era, including the Caravan, were consistently strong contenders on Car and Driver's 10 Best lists for their segment.
Ratings
Consumer Reports Ratings:
Ratings varied by year and specific model, with some praise for comfort and utility, and criticisms often directed at reliability for certain components.
Certifications
Federal Safety Standards:
Designed to meet all applicable Federal Motor Vehicle Safety Standards (FMVSS) for the respective model years.
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