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Chrysler Caravan 2003-2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Model Year Start: 2003 Model Year End: 2007 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience For Manual: DIY mechanics, independent repair shops, auto enthusiasts Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture Key Features Manual Advantage: Comprehensive, detailed, and covers a wide range of repairs and maintenance tasks. Vehicle Appeal: Practicality, spaciousness, family-oriented design 📋 Manual Details Coverage Areas Primary Coverage: North America Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Management: Diagnosis, repair, and overhaul of all gasoline engines including: 3.3L OHV V6 (VIN U), 3.8L OHV V6 (VIN L) Fuel System: Fuel injection system, fuel pump, fuel filter, fuel tank, evaporative emissions control (EVAP) Transmission Manual: 41TE (3-speed automatic), 42LE (4-speed automatic) - Diagnosis, overhaul, fluid changes, and repair procedures Drivetrain: Front-wheel drive (FWD) system, axles, CV joints, differential Suspension: Front and rear suspension components, shock absorbers, struts, springs, bushings, alignment specifications Steering: Power steering system, steering column, steering rack, tie rods, diagnosis and repair Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), parking brake, hydraulic system, bleeding procedures Electrical System: Battery, charging system, starting system, lighting, ignition system, fuses, relays Body Electrical: Power windows, power locks, power mirrors, remote keyless entry, interior lighting, exterior lighting HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant handling, component diagnosis and replacement Body And Frame: Exterior body panels, doors, hood, tailgate, interior trim, chassis and frame inspection Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement Diagnostic Troubleshooting: System-specific troubleshooting guides, DTC (Diagnostic Trouble Code) lookup and interpretation Component Replacement: Step-by-step instructions for replacing common wear items and major components Engine Overhaul: Detailed procedures for engine disassembly, inspection, and reassembly Transmission Rebuild: Comprehensive guides for rebuilding automatic transmissions Brake System Service: Pad and rotor replacement, caliper service, brake fluid flush and bleeding Electrical Component Testing: Testing of sensors, actuators, alternators, starters, and related wiring harnesses Technical Depth Depth Level: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Diagrams And Illustrations: Includes exploded views, wiring diagrams, and schematic illustrations Diagnostic Codes: Detailed listing and interpretation of OBD-II Diagnostic Trouble Codes (DTCs) 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for easy information retrieval Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper Quality: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 3.3L V6 (OHV, 12-Valve) Engine Displacement 1: 3.3 Liters (203 cubic inches) Engine Horsepower 1: Approx. 180 hp @ 5000 rpm Engine Torque 1: Approx. 205 lb-ft @ 3200 rpm Optional Engine Engine Code 2: 3.8L V6 (OHV, 12-Valve) Engine Displacement 2: 3.8 Liters (230 cubic inches) Engine Horsepower 2: Approx. 205 hp @ 5000 rpm Engine Torque 2: Approx. 235 lb-ft @ 3200 rpm Fuel System Fuel Induction: Multi-port Electronic Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Recommended Octane: 87 Octane 🔧 Transmission Standard Transmission Transmission Type 1: 41TE Automatic Transaxle (3-Speed) Optional Transmission Transmission Type 2: 42LE Automatic Transaxle (4-Speed) Features Transmission Control: Electronically Controlled Automatic Fluid Specifications Transmission Fluid Type: Chrysler ATF+4 (Mopar) Fluid Capacities Transmission Fluid Capacity 41Te: Approx. 4.1 quarts (3.9 liters) Transmission Fluid Capacity 42Le: Approx. 3.9 quarts (3.7 liters) 📐 Dimensions Exterior Wheelbase: Approx. 119.3 inches (3030 mm) Length: Approx. 189.8 inches (4821 mm) Width: Approx. 72.0 inches (1829 mm) Height: Approx. 68.1 inches (1730 mm) Cargo Max Cargo Volume: Approx. 142.5 cubic feet (4035 liters) Weights Curb Weight Start: Approx. 4000 lbs (1814 kg) Curb Weight End: Approx. 4500 lbs (2041 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: ★★★★★ (5-Star) NHTSA Front Impact Passenger: ★★★★★ (5-Star) NHTSA Side Impact Front Driver: ★★★★☆ (4-Star) NHTSA Side Impact Front Passenger: ★★★★☆ (4-Star) Active Features ABS: Standard Anti-lock Braking System (ABS) Passive Features Airbags Front: Standard front driver and passenger airbags Airbags Side: Optional side-impact airbags available on some trims Seatbelts: All seating positions equipped with three-point seatbelts 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with CD player; optional premium audio systems available Rear Entertainment: Optional rear-seat entertainment system with video screen and headphone jacks Driver Assistance Cruise Control: Standard cruise control Parking Assist: Optional rear parking assist sensors available on some trims Connectivity Remote Keyless Entry: Available remote keyless entry system 🔧 Maintenance Service Intervals Oil Change Interval Synthetic: 7,500-10,000 miles (12,000-16,000 km) or 6-12 months with synthetic oil Oil Change Interval Conventional: 3,000-5,000 miles (5,000-8,000 km) with conventional oil Engine Air Filter Replacement: Every 30,000 miles (48,000 km) or as needed Spark Plug Replacement 3.3L: Approx. 100,000 miles (160,000 km) with platinum-tipped plugs Spark Plug...
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Chrysler Caravan 2003-2007 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Model Year Start:
2003
Model Year End:
2007
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience For Manual:
DIY mechanics, independent repair shops, auto enthusiasts
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture
Key Features
Manual Advantage:
Comprehensive, detailed, and covers a wide range of repairs and maintenance tasks.
Vehicle Appeal:
Practicality, spaciousness, family-oriented design
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
Diagnosis, repair, and overhaul of all gasoline engines including: 3.3L OHV V6 (VIN U), 3.8L OHV V6 (VIN L)
Fuel System:
Fuel injection system, fuel pump, fuel filter, fuel tank, evaporative emissions control (EVAP)
Transmission Manual:
41TE (3-speed automatic), 42LE (4-speed automatic) - Diagnosis, overhaul, fluid changes, and repair procedures
Drivetrain:
Front-wheel drive (FWD) system, axles, CV joints, differential
Suspension:
Front and rear suspension components, shock absorbers, struts, springs, bushings, alignment specifications
Steering:
Power steering system, steering column, steering rack, tie rods, diagnosis and repair
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), parking brake, hydraulic system, bleeding procedures
Electrical System:
Battery, charging system, starting system, lighting, ignition system, fuses, relays
Body Electrical:
Power windows, power locks, power mirrors, remote keyless entry, interior lighting, exterior lighting
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant handling, component diagnosis and replacement
Body And Frame:
Exterior body panels, doors, hood, tailgate, interior trim, chassis and frame inspection
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement
Diagnostic Troubleshooting:
System-specific troubleshooting guides, DTC (Diagnostic Trouble Code) lookup and interpretation
Component Replacement:
Step-by-step instructions for replacing common wear items and major components
Engine Overhaul:
Detailed procedures for engine disassembly, inspection, and reassembly
Transmission Rebuild:
Comprehensive guides for rebuilding automatic transmissions
Brake System Service:
Pad and rotor replacement, caliper service, brake fluid flush and bleeding
Electrical Component Testing:
Testing of sensors, actuators, alternators, starters, and related wiring harnesses
Technical Depth
Depth Level:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Diagrams And Illustrations:
Includes exploded views, wiring diagrams, and schematic illustrations
Diagnostic Codes:
Detailed listing and interpretation of OBD-II Diagnostic Trouble Codes (DTCs)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for easy information retrieval
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Quality:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
3.3L V6 (OHV, 12-Valve)
Engine Displacement 1:
3.3 Liters (203 cubic inches)
Engine Horsepower 1:
Approx. 180 hp @ 5000 rpm
Engine Torque 1:
Approx. 205 lb-ft @ 3200 rpm
Optional Engine
Engine Code 2:
3.8L V6 (OHV, 12-Valve)
Engine Displacement 2:
3.8 Liters (230 cubic inches)
Engine Horsepower 2:
Approx. 205 hp @ 5000 rpm
Engine Torque 2:
Approx. 235 lb-ft @ 3200 rpm
Fuel System
Fuel Induction:
Multi-port Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 Octane
🔧 Transmission
Standard Transmission
Transmission Type 1:
41TE Automatic Transaxle (3-Speed)
Optional Transmission
Transmission Type 2:
42LE Automatic Transaxle (4-Speed)
Features
Transmission Control:
Electronically Controlled Automatic
Fluid Specifications
Transmission Fluid Type:
Chrysler ATF+4 (Mopar)
Fluid Capacities
Transmission Fluid Capacity 41Te:
Approx. 4.1 quarts (3.9 liters)
Transmission Fluid Capacity 42Le:
Approx. 3.9 quarts (3.7 liters)
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.3 inches (3030 mm)
Length:
Approx. 189.8 inches (4821 mm)
Width:
Approx. 72.0 inches (1829 mm)
Height:
Approx. 68.1 inches (1730 mm)
Cargo
Max Cargo Volume:
Approx. 142.5 cubic feet (4035 liters)
Weights
Curb Weight Start:
Approx. 4000 lbs (1814 kg)
Curb Weight End:
Approx. 4500 lbs (2041 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
★★★★★ (5-Star)
NHTSA Front Impact Passenger:
★★★★★ (5-Star)
NHTSA Side Impact Front Driver:
★★★★☆ (4-Star)
NHTSA Side Impact Front Passenger:
★★★★☆ (4-Star)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags Front:
Standard front driver and passenger airbags
Airbags Side:
Optional side-impact airbags available on some trims
Seatbelts:
All seating positions equipped with three-point seatbelts
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player; optional premium audio systems available
Rear Entertainment:
Optional rear-seat entertainment system with video screen and headphone jacks
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Optional rear parking assist sensors available on some trims
Connectivity
Remote Keyless Entry:
Available remote keyless entry system
🔧 Maintenance
Service Intervals
Oil Change Interval Synthetic:
7,500-10,000 miles (12,000-16,000 km) or 6-12 months with synthetic oil
Oil Change Interval Conventional:
3,000-5,000 miles (5,000-8,000 km) with conventional oil
Engine Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed
Spark Plug Replacement 3.3L:
Approx. 100,000 miles (160,000 km) with platinum-tipped plugs
Spark Plug Replacement 3.8L:
Approx. 100,000 miles (160,000 km) with platinum-tipped plugs
Fluid Specifications
Engine Oil Type 3.3L:
SAE 5W-30 (Synthetic recommended)
Engine Oil Type 3.8L:
SAE 5W-30 (Synthetic recommended)
Engine Oil Capacity 3.3L:
Approx. 4.5 quarts (4.3 liters) with filter
Engine Oil Capacity 3.8L:
Approx. 4.5 quarts (4.3 liters) with filter
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (Pink)
Known Issues
Common Wear Item:
Brake wear (front pads and rotors), exhaust system rust and leaks
Powertrain Concern:
Transmission solenoid issues (especially in earlier models), occasional oil leaks from valve cover gaskets or oil pan
Electrical Concern:
Power sliding door motor failure, HVAC blower motor resistor failure, intermittent power window issues
Suspension Concern:
Worn ball joints and tie rod ends, strut mounting issues
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler has a long history of innovation in the minivan segment, pioneering many features that became standard.
Model Evolution
Generation:
This generation (RS) represents a significant redesign from the previous model, focusing on improved aerodynamics, safety, and interior comfort.
Key Updates During Generation:
Introduction of optional all-wheel drive (AWD) in later years, powertrain enhancements, interior styling updates.
Production
Manufacturing Plant:
Windsor Assembly Plant, Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Segment Popularity:
The Chrysler Caravan was a consistent sales leader in the minivan segment for many years.
Safety Accolades:
Achieved good ratings in IIHS and NHTSA crash tests for its time, contributing to its popularity.
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