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2003-2007 Dodge Caravan Factory Service Repair Manual 2004 2005 2006

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered By Manual: 2003, 2004, 2005, 2006, 2007 Codes Platform: NS (North American minivan platform) 👋 Introduction Market Position Positioning: The Dodge Caravan has historically been a benchmark in the minivan segment, offering practicality, family-friendly features, and a range of powertrain options. This manual targets DIY enthusiasts, independent repair shops, and fleet maintenance operations seeking to service and maintain these vehicles effectively. Competitive Analysis Competitors: Ford Windstar, Toyota Sienna, Honda Odyssey, Chevrolet Venture/Montana, Pontiac Montana, Buick Terraza. Key Features Manual Benefits: Provides factory-level repair procedures, accurate diagnostic information, and detailed specifications, enabling cost-effective and correct servicing of the vehicle. The instant download feature offers immediate access to critical repair data. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Service Procedures Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Wiring Diagrams, Component Identification Page Count Estimated Page Count: Over 3000 pages (typical for comprehensive factory service manuals of this era) Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF/ZIP 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L V6, 3.8L V6), Transmission/Transaxle (4-speed Automatic, 6-speed Automatic for later models), Fuel System, Exhaust System, Cooling System, Ignition System, Lubrication System Chassis: Suspension (Front & Rear), Steering System, Brake System (Front Disc, Rear Drum/Disc), Driveline, Wheels & Tires Body: Body Construction, Bumpers, Frame, Doors, Windows, Interior Trim, Seats, Exterior Panels Electrical: Lighting Systems, Instrument Cluster, Audio System, Horn, Wipers/Washers, Power Systems (Windows, Locks, Seats), Vehicle Theft Security, Speed Control, Restraint Systems (Airbags), Electronic Control Modules (ECMs, TCMs, BCMs), Navigation/Telecommunication, Message Systems, Chime/Buzzer, Wiring Diagrams Comfort And Climate: Heating System, Air Conditioning (HVAC), Heated Systems Emissions: Emissions Control Systems, OBD-II Diagnostics Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Repair: Engine overhaul, transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair, body panel repair Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), component testing procedures, wiring harness tracing Installation: Component replacement, accessory installation guidance Technical Depth Depth: Comprehensive: Covers everything from basic fluid checks and component replacement to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. Utilizes factory-specific terminology and specifications. 📊 Manual Specifications File Format Format Details: PDF/ZIP. Requires unzipping software (e.g., WinRAR). PDF format typically allows for text searching, bookmarking, and printing. Print Quality Quality: Digital download, quality dependent on original factory scan. Typically high resolution for legibility of diagrams and text. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: 3.3L (201 cu in) OHV V6 (Chrysler EER/EGJ/EDZ engine code) and 3.8L (231 cu in) OHV V6 (Chrysler L32 engine code) Performance 3.3L V6 Horsepower: Approx. 180 hp @ 5000 rpm (varies slightly by year/application) 3.3L V6 Torque: Approx. 205 lb-ft @ 4000 rpm (varies slightly by year/application) 3.8L V6 Horsepower: Approx. 205 hp @ 5000 rpm (varies slightly by year/application) 3.8L V6 Torque: Approx. 240 lb-ft @ 4000 rpm (varies slightly by year/application) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Engine Construction Block Material: Cast Iron Cylinder Head Material: Aluminum 🔧 Transmission Standard Transmission Type: 4-speed Automatic (e.g., 41TE/42LE/45RFE family) Optional Transmission Type: 6-speed Automatic (introduced later in the generation, potentially for some 2007 models) Features Transmission Control: Electronic Control Unit (ECU) with diagnostic capabilities Fluid Requirements Fluid Type: ATF+4 (Automatic Transmission Fluid Type 9602) - Crucial specification for longevity 📐 Dimensions Exterior Wheelbase: Approx. 119.3 inches (standard wheelbase); Approx. 135.0 inches (long wheelbase - Grand Caravan) Length: Approx. 189.9 inches (standard wheelbase); Approx. 202.9 inches (long wheelbase) Weights Curb Weight: Approx. 4000 - 4500 lbs (depending on configuration and engine) Gross Vehicle Weight Rating: Approx. 5600 - 6000 lbs Cargo Cargo Volume Behind 3Rd Row: Approx. 30-40 cu ft (standard wheelbase); Approx. 45-55 cu ft (long wheelbase) Max Cargo Volume: Approx. 100-150 cu ft (with 2nd and 3rd rows folded/removed) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4 stars (2003-2007 model years, varies slightly) NHTSA Frontal Impact Passenger: 4 stars (2003-2007 model years, varies slightly) NHTSA Side Impact Front Seat: 5 stars (2003-2007 model years) NHTSA Side Impact Rear Seat: 4-5 stars (2003-2007 model years, varies slightly) IIHS Frontal Offset: Good (2003-2007 model years) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Electronic Stability: Optional Electronic Stability Control (ESC) on some later models Passive Features Airbags: Standard front driver and passenger airbags; Optional front side-impact airbags, optional rear side-impact airbags. Seat Belts: Three-point seat belts with pretensioners for all outboard seating positions. 💡 Technology Features Infotainment Audio Options: Factory AM/FM/CD player, optional CD/MP3 player, optional premium audio systems (e.g., Infinity), optional rear-seat entertainment systems. Driver Assistance Cruise Control: Standard Cruise Control on most trims. Connectivity Telematics: Optional Uconnect hands-free communication system...
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2003-2007 Dodge Caravan Factory Service Repair Manual 2004 2005 2006
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered By Manual:
2003, 2004, 2005, 2006, 2007
Codes
Platform:
NS (North American minivan platform)
👋 Introduction
Market Position
Positioning:
The Dodge Caravan has historically been a benchmark in the minivan segment, offering practicality, family-friendly features, and a range of powertrain options. This manual targets DIY enthusiasts, independent repair shops, and fleet maintenance operations seeking to service and maintain these vehicles effectively.
Competitive Analysis
Competitors:
Ford Windstar, Toyota Sienna, Honda Odyssey, Chevrolet Venture/Montana, Pontiac Montana, Buick Terraza.
Key Features
Manual Benefits:
Provides factory-level repair procedures, accurate diagnostic information, and detailed specifications, enabling cost-effective and correct servicing of the vehicle. The instant download feature offers immediate access to critical repair data.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and Service Procedures
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Wiring Diagrams, Component Identification
Page Count
Estimated Page Count:
Over 3000 pages (typical for comprehensive factory service manuals of this era)
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF/ZIP
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.3L V6, 3.8L V6), Transmission/Transaxle (4-speed Automatic, 6-speed Automatic for later models), Fuel System, Exhaust System, Cooling System, Ignition System, Lubrication System
Chassis:
Suspension (Front & Rear), Steering System, Brake System (Front Disc, Rear Drum/Disc), Driveline, Wheels & Tires
Body:
Body Construction, Bumpers, Frame, Doors, Windows, Interior Trim, Seats, Exterior Panels
Electrical:
Lighting Systems, Instrument Cluster, Audio System, Horn, Wipers/Washers, Power Systems (Windows, Locks, Seats), Vehicle Theft Security, Speed Control, Restraint Systems (Airbags), Electronic Control Modules (ECMs, TCMs, BCMs), Navigation/Telecommunication, Message Systems, Chime/Buzzer, Wiring Diagrams
Comfort And Climate:
Heating System, Air Conditioning (HVAC), Heated Systems
Emissions:
Emissions Control Systems, OBD-II Diagnostics
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Repair:
Engine overhaul, transmission repair, brake system repair, suspension component replacement, electrical component diagnosis and repair, body panel repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), component testing procedures, wiring harness tracing
Installation:
Component replacement, accessory installation guidance
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid checks and component replacement to full engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. Utilizes factory-specific terminology and specifications.
📊 Manual Specifications
File Format
Format Details:
PDF/ZIP. Requires unzipping software (e.g., WinRAR). PDF format typically allows for text searching, bookmarking, and printing.
Print Quality
Quality:
Digital download, quality dependent on original factory scan. Typically high resolution for legibility of diagrams and text.
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
3.3L (201 cu in) OHV V6 (Chrysler EER/EGJ/EDZ engine code) and 3.8L (231 cu in) OHV V6 (Chrysler L32 engine code)
Performance
3.3L V6 Horsepower:
Approx. 180 hp @ 5000 rpm (varies slightly by year/application)
3.3L V6 Torque:
Approx. 205 lb-ft @ 4000 rpm (varies slightly by year/application)
3.8L V6 Horsepower:
Approx. 205 hp @ 5000 rpm (varies slightly by year/application)
3.8L V6 Torque:
Approx. 240 lb-ft @ 4000 rpm (varies slightly by year/application)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Engine Construction
Block Material:
Cast Iron
Cylinder Head Material:
Aluminum
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic (e.g., 41TE/42LE/45RFE family)
Optional
Transmission Type:
6-speed Automatic (introduced later in the generation, potentially for some 2007 models)
Features
Transmission Control:
Electronic Control Unit (ECU) with diagnostic capabilities
Fluid Requirements
Fluid Type:
ATF+4 (Automatic Transmission Fluid Type 9602) - Crucial specification for longevity
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.3 inches (standard wheelbase); Approx. 135.0 inches (long wheelbase - Grand Caravan)
Length:
Approx. 189.9 inches (standard wheelbase); Approx. 202.9 inches (long wheelbase)
Weights
Curb Weight:
Approx. 4000 - 4500 lbs (depending on configuration and engine)
Gross Vehicle Weight Rating:
Approx. 5600 - 6000 lbs
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 30-40 cu ft (standard wheelbase); Approx. 45-55 cu ft (long wheelbase)
Max Cargo Volume:
Approx. 100-150 cu ft (with 2nd and 3rd rows folded/removed)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 stars (2003-2007 model years, varies slightly)
NHTSA Frontal Impact Passenger:
4 stars (2003-2007 model years, varies slightly)
NHTSA Side Impact Front Seat:
5 stars (2003-2007 model years)
NHTSA Side Impact Rear Seat:
4-5 stars (2003-2007 model years, varies slightly)
IIHS Frontal Offset:
Good (2003-2007 model years)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS)
Electronic Stability:
Optional Electronic Stability Control (ESC) on some later models
Passive Features
Airbags:
Standard front driver and passenger airbags; Optional front side-impact airbags, optional rear side-impact airbags.
Seat Belts:
Three-point seat belts with pretensioners for all outboard seating positions.
💡 Technology Features
Infotainment
Audio Options:
Factory AM/FM/CD player, optional CD/MP3 player, optional premium audio systems (e.g., Infinity), optional rear-seat entertainment systems.
Driver Assistance
Cruise Control:
Standard Cruise Control on most trims.
Connectivity
Telematics:
Optional Uconnect hands-free communication system on later models.
Navigation
Navigation System:
Optional factory-installed navigation system available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (for synthetic blend/full synthetic oil recommended by many service centers). Conventional oil may have a 3,000-5,000 mile interval.
Transmission Fluid Change Interval:
Every 60,000 - 100,000 miles or as per severe duty schedule, depending on usage. Crucial to use ATF+4.
Coolant Change Interval:
Initial change at 100,000 miles, then every 50,000 miles thereafter (using HOAT coolant).
Spark Plug Replacement:
3.3L V6: 100,000 miles; 3.8L V6: 100,000 miles (Long-life spark plugs)
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 API Certified (check owner's manual for specific recommendations)
Coolant Spec:
Mopar Antifreeze/Coolant (HOAT) - Orange/Pink color, or equivalent meeting Chrysler MS-9769
Brake Fluid Spec:
DOT 3
Power Steering Fluid Spec:
Mopar Power Steering Fluid or equivalent meeting Chrysler MS-5901
Known Issues
Common Problems Area 1:
Transmission problems: Torque converter shudder, failure of the input clutch apply system, internal seal leaks. Regular fluid and filter changes are critical.
Common Problems Area 2:
Rear axle seals leaking, coolant leaks (especially from intake manifold gaskets on some older Chrysler V6 engines, though less common on this specific generation). Evaporative Emission (EVAP) system leaks are also frequent.
Common Problems Area 3:
Power door lock actuators failing, power window motor issues, HVAC blower motor resistor failure.
Common Problems Area 4:
Sway bar links and bushings can wear, leading to clunking noises over bumps. Suspension components like ball joints and tie rod ends also require periodic inspection.
📚 Vehicle History
Brand Heritage
Dodge Heritage:
Dodge, a division of Chrysler (now Stellantis), has a long history of producing robust vehicles, including trucks and performance cars. The Caravan marked its significant entry into the family-oriented minivan market.
Model Evolution
Generation Overview:
The 2003-2007 models represent the fourth generation of the Dodge Caravan. This generation saw updates in styling, powertrain, interior features, and safety. It continued the minivan tradition of versatility and family utility.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
Production Years For Generation:
2001-2007
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Historically, the Caravan received mixed reviews from consumer organizations regarding reliability, often scoring average or below average in certain categories. However, its practicality and affordability kept it popular.
Car And Driver Awards:
Often listed on Car and Driver's '10Best' lists in earlier generations, but later generations competed in a more crowded and refined segment.
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