DODGE CARAVAN Petrol Diesel Service Repair Manual 2003-2007
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2003-2007 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Segment: Minivan / MPV Target Audience: Families, commercial use, DIY mechanics. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture. Key Features Versatility: Known for flexible seating, ample cargo space, and family-friendly features. Availability: Widely available with various engine and trim options, making it a popular choice in the segment. 📋 Manual Details Coverage Areas Primary Markets: North America Page Count Estimated Pages: Varies by specific engine/transmission, typically 2000+ pages for full factory coverage. Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (2.4L I4, 3.3L V6, 3.8L V6, 2.5L CRD Diesel), Transmission (4-speed Automatic, 5-speed Manual), Drivetrain (FWD) Chassis: Suspension (Front MacPherson Strut, Rear Twist Beam Axle), Steering (Power Rack and Pinion), Brakes (Front Ventilated Discs, Rear Drums/Discs) Electrical: Wiring Diagrams, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC, Lighting, Audio, Power Accessories Body: Exterior Body Panels, Interior Trim, Doors, Seats, Glass, Climate Control System Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Belt and Hose Inspections Repair: Engine Mechanical Repairs, Transmission Overhaul, Brake System Servicing, Suspension and Steering Component Replacement, Electrical Component Diagnosis and Replacement, Bodywork Repairs Diagnostics: Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Component Testing Procedures, Symptom-Based Diagnostics Technical Depth Depth: Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed specifications and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: Professional Quality, high detail, suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 2.4L Inline-4 (GEMA engine family) Engine 2: 3.3L V6 (EGA engine family) Engine 3: 3.8L V6 (EGH engine family) Engine 4: 2.5L CRD (Common Rail Diesel) Inline-4 (VM Motori) Performance 2.4L I4 Horsepower: Approx. 150 hp @ 5800 rpm 3.3L V6 Horsepower: Approx. 180 hp @ 5000 rpm 3.8L V6 Horsepower: Approx. 200 hp @ 5000 rpm 2.5L Crd Horsepower: Approx. 130-140 hp @ 4000 rpm (market dependent) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (2.4L, 3.3L, 3.8L), Diesel (2.5L CRD) 🔧 Transmission Standard Transmission 1: 4-speed Automatic (41TE/42LE) Optional Transmission 2: 5-speed Manual (NV1500 - less common, primarily on base models) Features Drivetrain: Front-Wheel Drive (FWD) 📐 Dimensions Exterior Wheelbase: Approx. 119.2 inches Length: Approx. 189.8 - 201.0 inches (depending on model variant) Width: Approx. 73.7 inches Height: Approx. 67.2 - 68.9 inches Interior Seating Capacity: 7-8 Passengers Cargo Cargo Volume Behind 3Rd Row: Approx. 21.0 - 32.0 cu ft Cargo Volume Max: Approx. 140.5 - 166.7 cu ft Weights Curb Weight: Approx. 3,700 - 4,200 lbs (depending on engine and features) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (2003-2007 models, some variations may exist) NHTSA Front Impact Passenger: 4 Stars (2003-2007 models, some variations may exist) NHTSA Side Impact Front Driver: 4 Stars (2003-2007 models, some variations may exist) NHTSA Side Impact Front Passenger: 4 Stars (2003-2007 models, some variations may exist) NHTSA Side Impact Rear Passenger: 4 Stars (2003-2007 models, some variations may exist) Active Features ABS: Standard on most models Traction Control: Optional on many models, standard on some higher trims/engines Electronic Stability Control: Optional on some models, particularly later years. Passive Features Airbags Front: Standard front driver and passenger airbags Airbags Side: Optional side curtain airbags available on some trims. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system 💡 Technology Features Infotainment Audio System: Available with AM/FM stereo, CD player, cassette player (early models), and optional Infinity premium audio system. Rear Entertainment: Optional rear-seat entertainment system (RSE) with DVD player and screens available on some trims. Driver Assistance Cruise Control: Standard on most models. Parking Sensors: Optional rear parking assist sensors on some later models. Connectivity Aux Input: Not commonly available for this generation. Aftermarket solutions may exist. Bluetooth: Not typically factory-installed. Aftermarket head units or adapters would be required. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months (synthetic blend recommended). Refer to manual for specific engine recommendations. Transmission Fluid Change: Every 60,000-100,000 miles depending on usage. Manual specifies interval and fluid type. Spark Plug Replacement: 3.3L/3.8L V6: 100,000 miles (long-life plugs). 2.4L I4: Varies, consult manual. Fluid Specifications Engine Oil Type: SAE 5W-20 or 5W-30 (check owner's manual for specific engine and temperature range requirements) Transmission Fluid Type: Chrysler ATF+4 (or equivalent approved fluid) Coolant Type: HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Mopar P/N 05103530AA or equivalent. Known Issues Cv Axles: Front CV joint wear, especially with higher mileage or aggressive driving. Transmission Solenoids: Failure of transmission solenoids can lead to shifting problems (e.g., failure...
Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed specifications and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
Professional Quality, high detail, suitable for printing.
Front CV joint wear, especially with higher mileage or aggressive driving.
Transmission Solenoids:
Failure of transmission solenoids can lead to shifting problems (e.g., failure to shift out of gear).
Power Steering Pump:
Leaking or failing power steering pump leading to noise or loss of assist.
Rear Hatch Struts:
Weakening or failing rear hatch struts.
Wheel Bearings:
Front wheel bearing wear causing noise and vibration.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing robust and practical vehicles, with a focus on performance and utility.
Model Evolution
Generation:
This period covers the third generation (NS) of the Dodge Caravan, introduced in 2001 (as a 2001 model) and updated for 2003 with a facelift and revised powertrain options.
Production
Manufacturing Plants:
Windsor Assembly Plant, Ontario, Canada; St. Louis Assembly Plant, Missouri, USA (operations moved/ceased later in the model run).
🏆 Awards & Recognition
Recognitions
Jdpowers Dependability:
While specific awards vary by year, the Dodge Caravan consistently ranked in the upper half of the minivan segment in J.D. Power studies for initial quality and dependability during its production run.
Consumer Reports:
Often cited for practicality and affordability by consumer organizations, though some powertrain components have received mixed reliability ratings.
Certifications
Safety Certifications:
Compliant with all Federal Motor Vehicle Safety Standards (FMVSS) for its model years.