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Dodge Caravan 2003-2007 Workshop Service Repair Manual Downl

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2003, 2004, 2005, 2006, 2007 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Segment: Minivan Target Audience: Professional Automotive...
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Dodge Caravan 2003-2007 Workshop Service Repair Manual Downl
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered:
2003, 2004, 2005, 2006, 2007
Codes
Platform:
NS (Third Generation)
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Professional Automotive Technicians, DIY enthusiasts with mechanical aptitude.
Competitive Analysis
Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture.
Key Features
Vehicle Attributes:
Spacious interior, flexible seating, Stow 'n Go seating (later models), practicality.
Manual Value Proposition:
Provides in-depth technical information crucial for accurate diagnosis and repair, reducing costly errors.
📋 Manual Details
Coverage Areas
Description:
Comprehensive coverage for all major mechanical, electrical, and body systems.
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system.
Drivetrain:
Automatic transmissions (41TE, 42LE, 45RFE), transaxle, drive axles, differentials.
Suspension Steering:
Front suspension (MacPherson struts, control arms), rear suspension (Torsion beam axle), power steering, steering column.
Brakes:
Front and rear disc brakes, anti-lock braking system (ABS), parking brake.
Electrical:
Battery, charging system, starting system, lighting, instruments, gauges, body electrical, power windows, power locks, power sliding doors, power liftgate.
HVAC:
Heating, ventilation, air conditioning (HVAC) system, climate control.
Body Interior:
Body construction, interior trim, seats, airbags, safety restraints, doors, liftgate, sliding doors, exterior trim.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement, brake pad replacement.
Diagnostics:
Troubleshooting common problems, diagnostic trouble codes (DTCs), wiring diagrams, component testing.
Repair:
Engine component repair/replacement, transmission overhaul, suspension component replacement, brake system repair, electrical component repair.
Disassembly Assembly:
Step-by-step instructions for component removal and installation.
Technical Depth
Depth:
Professional level, including detailed torque specifications, diagnostic procedures, and component diagrams.
📊 Manual Specifications
File Format
Searchable:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High-resolution for clear diagrams and text.
Binding Type
Format Type:
Downloadable PDF
Paper Type
Material Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
3.3L V6 (EGA)
Displacement 1:
3301 cc
Horsepower 1:
180 hp @ 5000 rpm
Torque 1:
205 lb-ft @ 3200 rpm
Optional Engine
Engine Code 2:
3.8L V6 (L32)
Displacement 2:
3778 cc
Horsepower 2:
200 hp @ 5200 rpm
Torque 2:
235 lb-ft @ 3600 rpm
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Induction:
Multi-port Electronic Fuel Injection (MPI)
Emission Controls:
Catalytic Converter, Oxygen Sensors (O2), EGR Valve.
🔧 Transmission
Standard
Transmission Type 1:
4-speed Automatic Transaxle (41TE)
Optional
Transmission Type 2:
4-speed Automatic Transaxle (42LE)
Transmission Type 3:
4-speed Automatic Transaxle (45RFE) - with 3.8L engine
Features
Transmission Fluid Spec 1:
ATF+4 (Chrysler Material Standard MS-9602)
Transmission Fluid Capacity 1:
Approximately 8.9 Liters (9.4 Quarts) for 41TE/42LE.
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
190.9 inches (4849 mm)
Width:
76.2 inches (1935 mm)
Height:
68.7 inches (1745 mm)
Cargo
Cargo Volume Behind First Row:
Approximately 142.5 cubic feet (4035 Liters)
Cargo Volume Behind Second Row:
Approximately 87.4 cubic feet (2475 Liters)
Weights
Curb Weight Approx:
4,200 - 4,500 lbs (1905 - 2041 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 stars (2003-2007 models varied slightly)
NHTSA Front Impact Passenger:
4 stars (2003-2007 models varied slightly)
IIHS Side Impact:
Acceptable/Good (depending on year and specific tests)
Active Features
ABS:
Standard on most trims
Traction Control:
Optional on some models
Passive Features
Airbags:
Frontal airbags, optional side airbags.
Seat Belts:
Three-point seat belts in all seating positions, integrated child seat anchors (LATCH).
💡 Technology Features
Infotainment
Audio Systems:
Factory AM/FM/CD, optional Infinity premium audio system, rear-seat entertainment systems (optional on later models).
Navigation:
Rare factory navigation options available on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions or specific models may have it.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (or per owner's manual, often 5,000 miles with synthetic oil).
Transmission Fluid Change Interval:
Typically 30,000 - 60,000 miles, depending on driving conditions.
Spark Plug Replacement Interval:
100,000 miles (Platinum or Iridium plugs).
Fluid Specifications
Engine Oil Type:
API Certified SAE 5W-30 (check owner's manual for specific temperature ranges).
Engine Oil Capacity:
3.3L: 4.5 Quarts (4.3 Liters) with filter; 3.8L: 4.5 Quarts (4.3 Liters) with filter.
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (color typically orange).
Coolant Capacity:
Approximately 12.5 Quarts (11.8 Liters).
Known Issues
Transmission Slipping:
Common issue, particularly in earlier models, often related to valve body or solenoid issues. Regular fluid changes can help.
Power Sliding Door Failure:
Motor, track, or cable issues can lead to malfunction. Requires specific diagnosis and repair procedures.
Ignition Coil Failure:
Individual ignition coils can fail, leading to misfires. Easy to diagnose and replace.
Oil Leaks:
Valve cover gaskets and oil pan gaskets are common leak points.
Heater Core Leaks:
Can lead to coolant loss and fogged windows; requires dashboard disassembly for replacement.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation, later DaimlerChrysler and Fiat Chrysler Automobiles.
Model Evolution
Generation:
Third Generation (NS) 2001-2007
Key Redesigns Within Generation:
Significant refresh for 2005 model year, including updated styling, interior, and powertrain improvements (Stow 'n Go seating introduced).
Production
Manufacturing Locations:
Windsor Assembly Plant, Windsor, Ontario, Canada.
🏆 Awards & Recognition
Recognitions
Model Reputation:
Consistently ranked as a popular and practical family vehicle, though often criticized for interior material quality in earlier years.
Kbb Value:
Generally good retained value for its segment, especially well-maintained examples.
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