Dodge Caravan 2003-2007 All Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Generation: Fourth Generation (RS) Codes Chassis Code: RS 👋 Introduction Market Position Segment: Minivan Target Audience: Families, small business owners, tradespeople requiring...

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Stichworte: 2003 2004 2005 2006 2007 Car Caravan Cars Dodge Misc

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Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Generation:

Fourth Generation (RS)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, small business owners, tradespeople requiring versatile cargo and passenger transport

Competitive Analysis

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana SV6, Kia Sedona, Mazda MPV

Key Features

Vehicle Appeal:

Spacious interior, flexible seating configurations (Stow 'n Go introduced later in generation), affordability, practicality

Manual Value Proposition:

Empowers DIY enthusiasts and professional technicians with in-depth knowledge to maintain and repair the Dodge Caravan efficiently and cost-effectively.

📋 Manual Details

Coverage Areas

Years Covered:

2003, 2004, 2005, 2006, 2007

Regions Covered:

North America

Page Count

Estimated Page Count:

2000+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, emission controls, engine performance diagnostics

Transmission:

Automatic transmission (40TE/41TE), clutch, drivetrain components, axle shafts, universal joints

Chassis:

Suspension (front and rear), steering system, braking system (ABS included), wheel alignment

Electrical:

Battery, charging system, starting system, lighting, instruments, wipers, horn, power accessories (windows, locks, mirrors), body control module (BCM), audio system, HVAC controls, trailer wiring

Body:

Body construction, exterior panels, interior trim, doors, windows, seats, roof, bumpers, glass replacement, body repair

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, fluid checks and replacements, filter replacements, tune-ups, belt replacement, brake service, tire rotation

Diagnostics:

Troubleshooting flowcharts, symptom-based diagnostics, diagnostic trouble codes (DTCs) explanation and clearing, component testing

Repair:

Component removal and installation, engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair

Special Tools:

Identification and usage of special tools required for specific repairs and adjustments

Technical Depth

Depth:

Comprehensive: from basic maintenance and troubleshooting to complete engine and transmission rebuilds, detailed electrical schematics, and body repair procedures

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text for quick access to information

Print Quality

Resolution:

High resolution for clear diagrams and text

Illustrations:

Detailed diagrams, illustrations, and photographs

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EDZ (3.3L V6)

Engine Type:

Overhead Valve (OHV) V6

Displacement:

3.3 Liters (201 cu in)

Bore X Stroke:

3.75 in x 3.23 in (95.25 mm x 82.04 mm)

Compression Ratio:

9.3:1

Horsepower:

180 hp @ 5000 rpm (approx.)

Torque:

205 lb-ft @ 3600 rpm (approx.)

Optional Engine

Engine Code:

U (4.0L SOHC V6 - Not typically found in this generation North American models, but included for completeness if used in specific markets or later models not explicitly stated in product name)

Engine Type:

Overhead Valve (OHV) V6

Displacement:

3.8 Liters (230 cu in)

Bore X Stroke:

3.91 in x 3.38 in (99.3 mm x 85.8 mm)

Compression Ratio:

9.4:1

Horsepower:

205 hp @ 5000 rpm (approx.)

Torque:

235 lb-ft @ 3600 rpm (approx.)

Fuel System

Injection Type:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Fuel Pump Pressure:

Approximately 31-45 psi

🔧 Transmission

Standard

Type:

40TE/41TE Automatic Transmission

Number Of Speeds:

4-Speed Automatic

Optional

Type:

N/A (Standard on all models covered)

Features

Overdrive:

Yes (4th gear)

Torque Converter Lockup:

Electronically controlled

Fluid Specifications

Fluid Type:

ATF+4 (Chrysler Material Standard MS-9602)

Fluid Capacity

Capacity:

Approximately 9.5 - 11.0 quarts (9.0 - 10.4 liters) for refill after drain and fill

📐 Dimensions

Exterior

Length:

Approximately 198.6 - 203.7 inches (5045 - 5174 mm) depending on configuration

Width:

Approximately 76.7 inches (1948 mm)

Height:

Approximately 67.5 - 69.0 inches (1715 - 1753 mm)

Wheelbase:

Approximately 120.0 inches (3048 mm)

Interior

Passenger Volume:

Approximately 150 - 160 cu ft (4.2 - 4.5 m³)

Cargo

Cargo Volume Behind 3Rd Row:

Approximately 30 - 36 cu ft (0.85 - 1.02 m³)

Cargo Volume Behind 2Nd Row:

Approximately 70 - 80 cu ft (1.98 - 2.26 m³)

Cargo Volume With All Seats Removed:

Approximately 140 - 150 cu ft (3.96 - 4.25 m³)

Weights

Curb Weight:

Approximately 4,000 - 4,500 lbs (1814 - 2041 kg)

Gross Vehicle Weight Rating Gvw:

Approximately 5,500 - 6,000 lbs (2495 - 2722 kg)

Towing Capacity:

Up to 3,800 lbs (1724 kg) with optional towing package

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test Driver:

Four Stars (2003-2004 models)

NHTSA Frontal Crash Test Passenger:

Four Stars (2003-2004 models)

NHTSA Side Impact Front Seat:

Five Stars (2003-2004 models)

NHTSA Side Impact Rear Seat:

Five Stars (2003-2004 models)

IIHS Offset Crash Rating:

Good (varies by year and specific test)

Active Features

Standard Anti-lock Braking System

Traction Control:

Optional (often linked with Electronic Stability Program - ESP)

Optional Electronic Stability Program (introduced in later years of this generation)

Passive Features

Airbags Front:

Standard advanced front airbags

Airbags Side:

Optional front-seat side airbags, available side-curtain airbags (later models)

Seatbelts:

Height-adjustable front seatbelts, all seating positions equipped with three-point seatbelts

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio Systems:

Base AM/FM/CD, optional AM/FM/CD/MP3, premium Infinity audio systems available.

Rear Seat Entertainment:

Optional rear-seat video system (RSE) with a flip-down screen and headphone jacks.

Driver Assistance

Cruise Control:

Standard on most trims

Park Assist:

Optional rear park assist sensors available on some models

Connectivity

Auxiliary Input:

Not commonly available from the factory; aftermarket solutions typically required.

Bluetooth:

Not available from the factory; aftermarket integration necessary.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 12,000-15,000 miles (19,000-24,000 km) or annually.

Transmission Fluid Service:

Every 30,000-60,000 miles (48,000-96,000 km) or every 2-3 years, depending on driving habits and fluid condition. Inspect regularly.

Spark Plug Replacement:

3.3L V6: Approx. 100,000 miles (160,000 km) with platinum-tipped plugs. 3.8L V6: Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Coolant Flush:

Every 30,000-60,000 miles (48,000-96,000 km) or 3-5 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (preferred), SAE 10W-30 or SAE 10W-40 acceptable depending on ambient temperature. API certified. Refer to manual for specific viscosity requirements.

Engine Oil Capacity:

3.3L V6: Approx. 4.5 quarts (4.3 liters). 3.8L V6: Approx. 5.0 quarts (4.7 liters). Includes filter.

Coolant Type:

Chrysler Type MS-7170 (OAT - Orange) or equivalent HOAT (Hybrid Organic Additive Technology) coolant. Typically a 50/50 mix with distilled water.

Power Steering Fluid:

ATF+4 or equivalent Mopar power steering fluid.

Brake Fluid Type:

DOT 3

Known Issues

Transmission Problems:

Common issues include torque converter shudder, premature wear of transmission clutches and bands, and solenoid pack failures. Regular fluid changes with correct fluid are critical.

Cooling System Issues:

Radiator leaks, hose failures, and water pump leaks can occur. Overheating issues are common if not maintained.

Exhaust System Issues:

Catalytic converter failure, exhaust manifold cracks (especially on 3.8L), and muffler/pipe corrosion are reported.

Suspension Component Wear:

Ball joints, tie rod ends, control arm bushings, and struts/shocks can wear out, leading to noise, vibration, and poor handling.

Power Door Lock Actuator Failure:

Actuators can fail, causing doors to not lock or unlock properly.

Cv Axle Boots Tears:

Tears in the CV axle boots can lead to grease leakage and eventual axle failure.

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge has a long history of producing robust and practical vehicles, with the Caravan pioneering the minivan segment.

Model Evolution

Generation Introduction:

The fourth generation (RS) debuted for the 2001 model year and received a significant refresh for 2005, including updated styling and powertrains.

Key Updates 2005 Refresh:

New front and rear fascias, updated interior with improved materials, introduction of the Stow 'n Go seating system (optional), potential for powertrain updates.

Production

Manufacturing Locations:

Windsor, Ontario, Canada (Dodge City plant); St. Louis, Missouri, USA

Production Years For Generation:

2001-2007

🏆 Awards & Recognition

Recognitions

Consumers Digest Best Buys:

The Dodge Caravan has often been recognized by publications like Consumers Digest as a Best Buy in the minivan category for its value and practicality.

Ratings

Edmunds Ratings:

Edmunds often provided practical reviews highlighting its family-friendly features and affordability, with ratings varying by specific model year and trim.

Certifications

Certification Type:

N/A (This refers to manual certifications, not vehicle certifications)