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DODGE CARAVAN Petrol Diesel Service Repair Manual 2003-2007

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Years Covered: 2003-2007 Codes Platform: NS (Third Generation) 👋 Introduction Market Position Segment: Minivan / MPV Target Audience: Families, commercial use, DIY...
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DODGE CARAVAN Petrol Diesel Service Repair Manual 2003-2007
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Years Covered:
2003-2007
Codes
Platform:
NS (Third Generation)
👋 Introduction
Market Position
Segment:
Minivan / MPV
Target Audience:
Families, commercial use, DIY mechanics.
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture.
Key Features
Versatility:
Known for flexible seating, ample cargo space, and family-friendly features.
Availability:
Widely available with various engine and trim options, making it a popular choice in the segment.
📋 Manual Details
Coverage Areas
Primary Markets:
North America
Page Count
Estimated Pages:
Varies by specific engine/transmission, typically 2000+ pages for full factory coverage.
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (2.4L I4, 3.3L V6, 3.8L V6, 2.5L CRD Diesel), Transmission (4-speed Automatic, 5-speed Manual), Drivetrain (FWD)
Chassis:
Suspension (Front MacPherson Strut, Rear Twist Beam Axle), Steering (Power Rack and Pinion), Brakes (Front Ventilated Discs, Rear Drums/Discs)
Electrical:
Wiring Diagrams, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC, Lighting, Audio, Power Accessories
Body:
Exterior Body Panels, Interior Trim, Doors, Seats, Glass, Climate Control System
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Belt and Hose Inspections
Repair:
Engine Mechanical Repairs, Transmission Overhaul, Brake System Servicing, Suspension and Steering Component Replacement, Electrical Component Diagnosis and Replacement, Bodywork Repairs
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Component Testing Procedures, Symptom-Based Diagnostics
Technical Depth
Depth:
Comprehensive: Covers all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed specifications and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
Professional Quality, high detail, suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.4L Inline-4 (GEMA engine family)
Engine 2:
3.3L V6 (EGA engine family)
Engine 3:
3.8L V6 (EGH engine family)
Engine 4:
2.5L CRD (Common Rail Diesel) Inline-4 (VM Motori)
Performance
2.4L I4 Horsepower:
Approx. 150 hp @ 5800 rpm
3.3L V6 Horsepower:
Approx. 180 hp @ 5000 rpm
3.8L V6 Horsepower:
Approx. 200 hp @ 5000 rpm
2.5L Crd Horsepower:
Approx. 130-140 hp @ 4000 rpm (market dependent)
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (2.4L, 3.3L, 3.8L), Diesel (2.5L CRD)
🔧 Transmission
Standard
Transmission 1:
4-speed Automatic (41TE/42LE)
Optional
Transmission 2:
5-speed Manual (NV1500 - less common, primarily on base models)
Features
Drivetrain:
Front-Wheel Drive (FWD)
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.2 inches
Length:
Approx. 189.8 - 201.0 inches (depending on model variant)
Width:
Approx. 73.7 inches
Height:
Approx. 67.2 - 68.9 inches
Interior
Seating Capacity:
7-8 Passengers
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 21.0 - 32.0 cu ft
Cargo Volume Max:
Approx. 140.5 - 166.7 cu ft
Weights
Curb Weight:
Approx. 3,700 - 4,200 lbs (depending on engine and features)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (2003-2007 models, some variations may exist)
NHTSA Front Impact Passenger:
4 Stars (2003-2007 models, some variations may exist)
NHTSA Side Impact Front Driver:
4 Stars (2003-2007 models, some variations may exist)
NHTSA Side Impact Front Passenger:
4 Stars (2003-2007 models, some variations may exist)
NHTSA Side Impact Rear Passenger:
4 Stars (2003-2007 models, some variations may exist)
Active Features
ABS:
Standard on most models
Traction Control:
Optional on many models, standard on some higher trims/engines
Electronic Stability Control:
Optional on some models, particularly later years.
Passive Features
Airbags Front:
Standard front driver and passenger airbags
Airbags Side:
Optional side curtain airbags available on some trims.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
Available with AM/FM stereo, CD player, cassette player (early models), and optional Infinity premium audio system.
Rear Entertainment:
Optional rear-seat entertainment system (RSE) with DVD player and screens available on some trims.
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Optional rear parking assist sensors on some later models.
Connectivity
Aux Input:
Not commonly available for this generation. Aftermarket solutions may exist.
Bluetooth:
Not typically factory-installed. Aftermarket head units or adapters would be required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months (synthetic blend recommended). Refer to manual for specific engine recommendations.
Transmission Fluid Change:
Every 60,000-100,000 miles depending on usage. Manual specifies interval and fluid type.
Spark Plug Replacement:
3.3L/3.8L V6: 100,000 miles (long-life plugs). 2.4L I4: Varies, consult manual.
Fluid Specifications
Engine Oil Type:
SAE 5W-20 or 5W-30 (check owner's manual for specific engine and temperature range requirements)
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent approved fluid)
Coolant Type:
HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Mopar P/N 05103530AA or equivalent.
Known Issues
Cv Axles:
Front CV joint wear, especially with higher mileage or aggressive driving.
Transmission Solenoids:
Failure of transmission solenoids can lead to shifting problems (e.g., failure to shift out of gear).
Power Steering Pump:
Leaking or failing power steering pump leading to noise or loss of assist.
Rear Hatch Struts:
Weakening or failing rear hatch struts.
Wheel Bearings:
Front wheel bearing wear causing noise and vibration.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing robust and practical vehicles, with a focus on performance and utility.
Model Evolution
Generation:
This period covers the third generation (NS) of the Dodge Caravan, introduced in 2001 (as a 2001 model) and updated for 2003 with a facelift and revised powertrain options.
Production
Manufacturing Plants:
Windsor Assembly Plant, Ontario, Canada; St. Louis Assembly Plant, Missouri, USA (operations moved/ceased later in the model run).
🏆 Awards & Recognition
Recognitions
Jdpowers Dependability:
While specific awards vary by year, the Dodge Caravan consistently ranked in the upper half of the minivan segment in J.D. Power studies for initial quality and dependability during its production run.
Consumer Reports:
Often cited for practicality and affordability by consumer organizations, though some powertrain components have received mixed reliability ratings.
Certifications
Safety Certifications:
Compliant with all Federal Motor Vehicle Safety Standards (FMVSS) for its model years.
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