DODGE CARAVAN 2003-2005 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2003, 2004, 2005 Generation Generation Code: RS Codes Platform: Chrysler RS platform (long wheelbase variant of the NS platform) 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, commercial users, DIY mechanics Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Plymouth Voyager/Grand Voyager, Chrysler Town & Country Key Features Versatility: Known for its spacious interior, flexible seating configurations, and Stow 'n Go (though optional and might vary by year/trim) Value Proposition: Offered a strong balance of space, features, and affordability in its class 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Dodge Caravan 2003-2005 models Secondary Coverage: All major repair and maintenance aspects Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive factory service manuals of this era) Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (e.g., PDF), Printable 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control Transmission: Automatic Transaxle (41TE/42LE variants), Clutch, Drivetrain Brakes: Front and rear brakes, ABS, parking brake Electrical: Battery, charging system, starting system, lighting, instruments, interior/exterior electronics, power accessories, wiring diagrams Chassis: Suspension (front and rear), steering, wheels, tires Body: Exterior body panels, interior trim, doors, windows, seats, HVAC system, body control modules Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Diagnostic procedures, fault code interpretation, symptom-based diagnostics Repair: Component removal, installation, disassembly, assembly, adjustments Diagnostics: On-board diagnostics (OBD-II), scan tool usage, sensor testing Technical Depth Depth: Full rebuild procedures, component-level diagnostics, wiring schematics, torque specifications, tolerances 📊 Manual Specifications File Format Digital Format: PDF Print Quality Print Readability: High resolution, clear diagrams, searchable text Binding Type Physical Binding: Not Applicable (digital format implies no physical binding) Paper Type Physical Paper Type: Not Applicable (digital format implies no physical paper type) ⚙️ Engine Specifications Primary Engine Engine Code: EGA Engine Type: 3.3L V6 OHV 12-Valve Bore X Stroke: 3.80 in x 3.81 in (96.5 mm x 96.8 mm) Displacement: 3301 cc (201.5 cu in) Compression Ratio: 9.0:1 Horsepower (@Rpm): Approx. 180 hp @ 4800 RPM (for 2003-2004) Torque (@Rpm): Approx. 205 lb-ft @ 3200 RPM (for 2003-2004) Optional Engine Engine Code Optional: ERG Engine Type Optional: 3.8L V6 OHV 12-Valve (Available on some higher trims/later models) Horsepower Optional (@Rpm): Approx. 200-215 hp @ 4800-5000 RPM Torque Optional (@Rpm): Approx. 230-240 lb-ft @ 3600-3800 RPM Fuel System Fuel Delivery: Multi-port Electronic Fuel Injection (MPI) Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 18.2 gallons (69 liters) 🔧 Transmission Standard Transmission Type Std: 4-Speed Automatic Transaxle (41TE or 42LE) Optional Transmission Type Opt: Not Applicable (4-speed auto was standard across most models) Features Transmission Features: Electronically controlled, adaptive shift logic Fluid Specifications Automatic Transmission Fluid Type: ATF+4 (Mopar) Fluid Capacities Automatic Transmission Fluid Capacity: Approx. 6.2 quarts (5.9 liters) for a drain and fill 📐 Dimensions Exterior Wheelbase: 119.2 inches (3028 mm) Length: 193.7 inches (4920 mm) Width: 76.0 inches (1930 mm) Height: 67.5 inches (1715 mm) Interior Passenger Volume: Approx. 140-160 cubic feet (varies by seating configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 14-20 cubic feet Cargo Volume Behind 2Nd Row: Approx. 70-80 cubic feet Cargo Volume All Seats Folded: Approx. 140-160 cubic feet Weights Curb Weight: Approx. 4000-4400 lbs (1814-2000 kg) Gross Vehicle Weight Rating (Gvwr): Approx. 5700-5900 lbs (2585-2676 kg) 🛡️ Safety Features Ratings NHTSA Frontal Driver Side: Good (2003-2004 models) NHTSA Frontal Passenger Side: Good (2003-2004 models) IIHS Frontal Offset: Acceptable (2003-2004 models) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional (Traction Control System - TCS) Electronic Stability Control: Not typically available on this generation Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front-seat side airbags Seatbelts: 3-point seatbelts for all seating positions, front seatbelt pretensioners 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette player, and premium sound systems (e.g., Infinity). Rear Entertainment: Optional rear-seat entertainment system with video screens and headphone jacks available on higher trims. Driver Assistance Cruise Control: Standard cruise control Connectivity Auxiliary Inputs: No standard auxiliary inputs or USB ports for this era. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to owner's manual for specific recommendations) Air Filter Replacement: Every 15,000-30,000 miles or as needed based on inspection Spark Plug Replacement: Typically every 30,000-100,000 miles, depending on spark plug type (e.g., platinum or iridium recommended for longer life) Transmission Fluid Change: Every 30,000-60,000 miles for optimal performance and longevity Fluid Specifications Engine Oil Type Viscosity: SAE 5W-30 (check owner's manual for specific Mopar approval) Coolant Type: Chrysler/Mopar Antifreeze/Coolant (OAT - Organic Additive Technology), usually HOAT orange type. Check manual for specific P/N. Fluid...
Worn ball joints, tie rod ends, control arm bushings, and sway bar links. Power steering leaks.
Common Problems Electrical:
Instrument cluster failures, power window/lock actuators, HVAC blower motor resistor, door lock actuators.
Common Problems Brakes:
Brake pad and rotor wear, seized caliper pins, parking brake issues.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing reliable and practical vehicles, often focusing on value and utility.
Model Evolution
Caravan Origin:
The Dodge Caravan, along with its Plymouth Voyager sibling, pioneered the minivan segment in the early 1980s.
Generation Details:
This 2003-2005 range represents the latter part of the third generation (RS/NS), known for significant updates over its predecessors.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years For Generation:
1996-2007 (RS platform was an evolution of NS)
🏆 Awards & Recognition
Recognitions
Editor Pick:
Consistently recognized by automotive critics and publications for its practicality, versatility, and value in the minivan segment during its production run.
Ratings
Kbb Value Rating:
Often received favorable ratings for its resale value and overall cost of ownership, especially for a family vehicle.