🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Model Variant:

Town & Country

Year:

2003

Engine Type:

Diesel

Chassis Code:

NS (Third Generation)

👋 Introduction

Category:

Minivan

Target Audience:

Automotive technicians, DIY enthusiasts, fleet maintenance personnel working on 2003 Dodge Caravan/Town & Country Diesel models.

Key Competitors:

Chevrolet Venture/Vans, Ford Windstar, Honda Odyssey, Toyota Sienna.

Manual Value Proposition:

Provides professional-grade repair and maintenance information, empowering owners and technicians to accurately diagnose and repair their vehicle, saving time and money.

Vehicle Distinction:

The availability of a diesel engine option in the Caravan/Town & Country lineup was less common in the North American market, making this manual particularly valuable for owners of this specific configuration.

📋 Manual Details

Coverage Scope:

Comprehensive Service and Repair

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive service manuals of this era)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, assembly, and torque specifications for all engine components (cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valvetrain).

Engine Fuel System:

Diesel fuel injection system components (injectors, pump, lines), fuel filter replacement, high-pressure fuel system diagnostics and repair, glow plug system.

Engine Lubrication:

Oil pump, oil pan, oil filter specifications, oil change procedures, lubrication points.

Engine Cooling:

Radiator, water pump, thermostat, coolant hoses, cooling fan operation, flushing and filling procedures.

Engine Ignition Starting:

Glow plug system operation and testing, starter motor, battery testing and replacement.

Transmission Automatic:

Transmission overhaul, fluid and filter change, torque converter service, shift control diagnosis, electronic transmission control unit (ETCU) diagnostics.

Drivetrain:

Front-wheel drive axles, CV joints, differential service, drive shaft inspection.

Brakes:

Hydraulic system diagnosis, disc brake pad and rotor replacement, caliper service, brake fluid specifications and bleeding procedures, parking brake adjustment.

Suspension:

Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), wheel alignment specifications, steering linkage.

Steering:

Power steering system diagnosis, fluid replacement, steering column, steering rack or gearbox service.

Electrical System Charging:

Alternator testing and replacement, battery charging systems, wiring diagrams for charging circuits.

Electrical System Starting:

Starter motor operation and testing, ignition switch functionality.

Lighting:

Headlight, taillight, interior lighting diagnostics and bulb replacement, wiring diagrams for lighting circuits.

Instrument Panel:

Gauge cluster diagnostics, warning lights, sensor inputs.

Body And Chassis:

Body panel removal and installation, door mechanisms, tailgate operation, interior trim removal, chassis structural information.

HVAC:

Air conditioning system service, refrigerant handling, heater core replacement, blower motor diagnosis, climate control systems.

Safety Systems:

Airbag system diagnostics, seat belt mechanisms, ABS (Anti-lock Braking System) component testing and troubleshooting.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool usage, troubleshooting flowcharts.

Scheduled Maintenance:

Detailed procedures for all scheduled maintenance tasks, including oil changes, filter replacements, fluid checks, and component inspections.

Troubleshooting:

Systematic troubleshooting guides and flowcharts for diagnosing common and complex vehicle issues.

Repair Procedures:

Step-by-step repair instructions for virtually every component and system on the vehicle, from minor adjustments to major component overhauls.

Component Removal Installation:

Detailed instructions on how to safely remove and reinstall all major and minor components.

Technical Specifications:

Torque specifications, clearances, fluid capacities, and other critical technical data for all repair and maintenance procedures.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, essential for electrical troubleshooting and repair.

Diagnostic Charts:

Diagnostic charts to help identify the root cause of problems based on symptoms.

Depth:

Expert Level: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.

📊 Manual Specifications

Format:

PDF

Compatibility:

All versions of Windows and Mac

Requirements:

Adobe PDF Reader

Searchability:

Likely text-searchable PDF for easy navigation.

Quality:

High-resolution, ensuring readability of text and diagrams.

Type:

Digital (PDF), allowing for easy access and printing of specific sections.

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code:

Likely 2.5L VM Motori Turbocharged Diesel (R425 or similar variant common in Chrysler products of the era)

Engine Family:

VM Motori

Displacement:

Approximately 2.5 Liters (2499 cc)

Configuration:

Inline-4 Cylinder

Aspiration:

Turbocharged

Horsepower Estimate:

Approximately 115-120 HP (specific output may vary)

Torque Estimate:

Approximately 200-220 lb-ft (specific output may vary)

Injection Type:

Direct Injection (likely common rail or unit injector system depending on specific VM Motori variant)

Fuel Type:

Diesel Fuel

🔧 Transmission

Type:

Likely a heavy-duty automatic transmission (e.g., Chrysler's 41TE or similar, adapted for diesel torque) or a manual transmission option.

Type:

Details on specific transmission options would be in the manual.

Transmission Fluid:

Specific ATF type required (e.g., ATF+4 or equivalent specified by VM Motori/Chrysler).

📐 Dimensions

Body Styles:

Minivan (Standard Wheelbase and Grand Caravan Long Wheelbase)

Cv Variant Features:

Optional deleted side windows, composite panels, optional rear seats, plastic cargo floor (bedliner-like), rubber flooring, standard hatch.

Curb Weight:

Varies by configuration, typically around 3800-4200 lbs for diesel models.

🛡️ Safety Features

NHTSA Ratings 2003:

Frontal Impact: 4/5 Stars, Side Impact: 4/5 Stars (specific ratings for individual model year may vary, general trend for the generation).

ABS:

Standard on most trims, Anti-lock Braking System.

Traction Control:

Optional on some models.

Airbags:

Driver and passenger front airbags standard. Optional side airbags may be available.

Seatbelts:

All seating positions equipped with three-point seat belts. Integrated child seat anchors (LATCH).

💡 Technology Features

Audio System:

Factory AM/FM/CD or Cassette player. Optional premium audio systems may be available.

Cruise Control:

Standard on most trims.

Trailer Tow:

Optional trailer tow package often available.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type. Consult manual for specific diesel recommendations.

Fuel Filter Replacement:

Recommended every 15,000-30,000 miles for diesel fuel filters. Critical for preventing injector damage.

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed or every 30,000 miles. Crucial for diesel engine performance.

Transmission Service:

Fluid and filter change typically every 30,000-60,000 miles. Refer to manual for specific diesel transmission service intervals.

Engine Oil:

API CG-4 or CH-4 rated diesel engine oil, SAE 15W-40 or 5W-40 (synthetic) recommended for diesel engines. Consult manual for exact viscosity and API service classification.

Coolant:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT 50/50 mix or equivalent.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent.

Common Diesel Issues:

Clogged fuel filters, injector issues, turbocharger problems, EGR valve issues, potential head gasket leaks (though less common on these specific diesel variants than some other diesels of the era).

Common Caravan Issues:

Transmission issues (especially with higher mileage), power window regulators, HVAC blower motor, door lock actuators.

📚 Vehicle History

Heritage Contribution:

Dodge Caravan pioneered the minivan segment, revolutionizing family transportation.

Generation:

Third Generation (NS) 1996-2000, Facelifted in 2001 (with minor updates continuing to 2007). This 2003 model is part of the facelifted third generation.

Cv Return 2003:

The Caravan C/V and Grand Caravan C/V returned in 2003 after a hiatus, offering a more cargo-oriented configuration.

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant).

🏆 Awards & Recognition

Segment Awards:

The Dodge Caravan/Town & Country consistently ranked high in minivan segment awards for practicality, versatility, and value during its production run.